Welding system

Abstract

The present disclosure relates to a welding system. The welding system is suitable for a to-be-welded piece with any one of a Y-shaped groove, a V-shaped groove and a U-shaped groove. The welding system comprises an impact gun, a displacement device and a control assembly. The impact gun is used for removing welding slag. The displacement device drives the impact gun to move relative to the to-be-welded piece. The control assembly is configured to control the displacement device to swing back and forth in the width direction and further configured to control the displacement device to stop moving in the depth direction when the displacement device drives the impact gun to move in the depth direction till the impact head at the end of the impact gun abuts against the surface of the weld joint. And in the welding process, when the extrusion state between the impact head and the weld joint surface reaches a set condition, the displacement device is controlled to be away from the weld joint surface in the depth direction. In the welding process, the impact head is in the state that the impact head makes contact with the surface of a weld joint without excessive extrusion, flexible slag removal is achieved, and therefore the slag removal effect is improved, and the welding quality is improved.

Description

Technical Field

[0001] This application relates to the field of mechanical parts processing technology, specifically to a welding system. Background Technology

[0002] During the welding process, oxide scale and other welding slag are inevitably generated, especially for welds requiring multiple layers and welding methods using flux-cored wire. After welding, a large amount of oxide scale adheres to the weld surface. If not removed, the oxide scale will prevent the weld layer from fully melting when welding the next layer, leading to welding defects. Therefore, removing the oxide scale between layers (also known as slag removal) is an important auxiliary process for improving welding quality.

[0003] It should be noted that the statements in this background section only provide background information relevant to this application and do not necessarily constitute prior art. Summary of the Invention

[0004] This application provides a welding system to improve welding quality.

[0005] This application provides a welding system suitable for workpieces having any one of Y-groove, V-groove, and U-groove designs. The workpiece has an annular welding area and is rotatably positioned for welding the welding area during rotation. The welding system includes an impact gun, a displacement device, and a control assembly. The impact gun is configured to strike the weld surface during welding to remove weld slag. The displacement device is used to move the impact gun relative to the workpiece along the depth and width directions of the groove. The control assembly is used to control the movement of the displacement device during welding to remove weld slag at different locations. The control assembly is configured to control the displacement device to reciprocate along the width direction. The control assembly is also configured to stop the displacement device from moving along the depth direction when the impact head at the end of the impact gun touches the weld surface, and to control the displacement device to move away from the weld surface along the depth direction when the pressure between the impact head and the weld surface reaches a set condition during welding.

[0006] In some embodiments, the control component is further configured to adjust the amount of oscillation of the displacement device in the width direction based on the amount of displacement of the displacement device in the depth direction when the displacement device is moved away from the weld surface in the depth direction.

[0007] In some embodiments, adjusting the amount of oscillation of the displacement device along the width direction based on the amount of displacement of the displacement device along the depth direction includes: increasing the amount of oscillation of the displacement device along the width direction.

[0008] In some embodiments, adjusting the oscillation amount of the displacement device along the width direction based on the displacement amount of the displacement device along the depth direction includes: pre-constructing and storing the correspondence between the displacement amount of the displacement device along the depth direction and the oscillation amount along the width direction for each weld cross-section feature according to different weld cross-section features; retrieving the corresponding correspondence according to different workpieces to be welded; and controlling the movement of the displacement device according to the correspondence during the welding process.

[0009] In some embodiments, the device further includes a base and an elastic element. The base is connected to the displacement device, one end of the elastic element is connected to the base, and the other end of the elastic element is connected to the impact gun. Controlling the displacement device to stop moving in the depth direction when the displacement device moves the impact gun along the depth direction until the top of the impact head of the impact gun touches the weld surface includes: when the displacement device moves the base along the depth direction until the top of the impact head touches the weld surface and the elastic element is compressed to a first compression amount, the control component controls the displacement device to stop moving in the depth direction.

[0010] In some embodiments, the device further includes a base and an elastic element. The base is connected to the displacement device, one end of the elastic element is connected to the base, and the other end of the elastic element is connected to the impact gun. Controlling the displacement device to move away from the weld surface in the depth direction when the extrusion state between the impact head and the weld surface reaches a set condition during the welding process includes: when the extrusion pressure between the impact head and the weld surface increases to the point that the elastic element is compressed to a second compression amount, controlling the displacement device to drive the base away from the weld surface in the depth direction.

[0011] In some embodiments, controlling the displacement device to move away from the weld surface along the depth direction includes: controlling the displacement device to move the base along the depth direction until the compression of the elastic element decreases from a second compression to a third compression.

[0012] In some embodiments, the control component includes a controller and a sensor, the sensor being used to detect the amount of compression of the elastic element, and the controller being used to control the motion state of the displacement device based on the amount of compression.

[0013] In some embodiments, the sensor includes a photoelectric switch, and the control component further includes a trigger plate. The photoelectric switch is fixedly disposed relative to the base, and the trigger plate is fixedly disposed relative to the impact gun. The trigger plate is configured to move relative to the photoelectric switch along the depth direction to switch the on / off state of the light path of the photoelectric switch to trigger a control signal. The controller controls the displacement device to operate according to the control signal.

[0014] In some embodiments, the photoelectric switch includes a first photoelectric switch and a second photoelectric switch. The trigger plate has a first shielding portion and a second shielding portion, which are spaced apart in the depth direction. When the displacement device moves the base along the depth direction until the top of the impact head touches the weld surface, the second shielding portion is located outside the U-shaped groove of the second photoelectric switch, and the first shielding portion moves into the U-shaped groove of the first photoelectric switch. The light path of the first photoelectric switch is blocked and a first control signal is triggered. The controller controls the displacement device to stop moving along the depth direction according to the first control signal. During the welding process, when the impact head is squeezed between the impact head and the weld surface until the second shielding portion moves into the U-shaped groove of the second photoelectric switch, the light path of the second photoelectric switch is blocked and a second control signal is triggered. The controller controls the displacement device to move the base away from the weld surface along the depth direction according to the second control signal.

[0015] In some embodiments, the output power of the impact gun is adjustable, and the control component is configured to control the impact gun to operate at a first power during welding to remove weld slag, and to control the impact gun to operate at a second power after welding to remove residual stress in the weld, the second power being greater than the first power.

[0016] In some embodiments, the displacement device includes a first translation mechanism and a second translation mechanism. The second translation mechanism is disposed on the first translation mechanism, and the impact gun is connected to the second translation mechanism. The first translation mechanism is used to drive the impact gun to move along the width direction, and the second translation mechanism is used to drive the impact gun to move along the depth direction.

[0017] According to the technical solution provided in this application, the welding system is applicable to workpieces with any one of Y-groove, V-groove, and U-groove designs. The workpiece has an annular welding area and is rotatably positioned for welding the welding area during rotation. The welding system includes an impact gun, a displacement device, and a control assembly. The impact gun is configured to strike the weld surface during welding to remove weld slag. The displacement device is used to move the impact gun relative to the workpiece along the depth and width directions of the groove. The control assembly is used to control the movement of the displacement device during welding to remove weld slag at different locations. The control assembly is configured to control the reciprocating oscillation of the displacement device along the width direction. The control assembly is also configured to stop the displacement device from moving along the depth direction when the impact head at the end of the impact gun touches the weld surface, and to control the displacement device to move away from the weld surface along the depth direction when the pressure between the impact head and the weld surface reaches a set condition during welding. It can ensure that the impact head is in contact with the weld surface without excessive pressure during the welding process, realizing flexible and automated slag removal, reducing the damage to the weld surface during the slag removal process, thereby improving the slag removal effect and welding quality, while not affecting the welding process. It realizes flexible slag removal and welding simultaneously, improving processing efficiency.

[0018] Other features and advantages of this application will become clear from the following detailed description of exemplary embodiments with reference to the accompanying drawings. Attached Figure Description

[0019] The accompanying drawings, which are included to provide a further understanding of this disclosure and form part of this application, illustrate exemplary embodiments of this disclosure and are used to explain this disclosure, but do not constitute an undue limitation of this disclosure. In the drawings:

[0020] Figure 1 This is a schematic diagram of the welding system according to some embodiments of this application.

[0021] Figure 2 This is a schematic diagram of the connection between the displacement device and the impact gun in some embodiments of this application.

[0022] Figure 3 for Figure 2 A magnified view of a portion of the sensor and trigger plate.

[0023] Figure 4 This is a schematic diagram of the structure of the trigger chip in some embodiments of this application.

[0024] Figure 5 This is a schematic diagram of the displacement amount of the displacement device for adjusting the displacement during V-groove welding according to some embodiments of this application.

[0025] Explanation of reference numerals in the attached figures:

[0026] 1. Impact gun; 2. Displacement device; 21. First translation mechanism; 22. Second translation mechanism; 3. Base; 4. Elastic element; 5. Photoelectric switch; 51. First photoelectric switch; 52. Second photoelectric switch; 6. Trigger plate; 61. First shielding part; 62. Second shielding part; 7. Weld seam positioning system; 8. Welding positioner. Detailed Implementation

[0027] Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The descriptions of the exemplary embodiments are merely illustrative and are in no way intended to limit the present disclosure or its application or use. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangement of components and steps, the composition of materials, numerical expressions, and values ​​set forth in these embodiments should be interpreted as exemplary only and not as limiting.

[0028] The terms "first," "second," and similar words used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Words such as "including" or "contains" mean that the element preceding the word encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well. Terms such as "above," "below," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, this relative positional relationship may also change accordingly.

[0029] In this disclosure, when a specific device is described as being located between a first device and a second device, an intermediary device may or may not be present between the specific device and the first or second device. When a specific device is described as being connected to other devices, the specific device may be directly connected to the other devices without an intermediary device, or it may be not directly connected to the other devices but have an intermediary device.

[0030] All terms used in this disclosure (including technical or scientific terms) have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in a general dictionary, such as a dictionary, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and not as having an idealized or highly formalized meaning, unless expressly defined herein.

[0031] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0032] The applicant's research found that existing technical solutions generally involve temporarily stopping the machine during welding, manually using tools such as files and small hammers to tap or grind the oxide scale area to remove it, and then restarting the machine to continue welding. Some patents have also designed automated slag removal devices, which involve using a motor or air source to rotate a steel needle at a distance from the weld pool and at a solidified weld location to tap or grind the weld and roughly remove the slag from the weld location.

[0033] Regarding the two slag removal methods mentioned above, firstly, manual knocking or grinding of the oxide scale using tools such as files and hammers requires stopping the welding production line, reducing processing efficiency. Secondly, because welding will continue afterward, slag removal cannot wait for the weld to cool down; it must be done while the weld is hot, posing a risk of burns. Some patented designs use a motor or pneumatic source to drive groups of steel needles for slag removal, but this has the following problems: Firstly, the impact or grinding force of the steel needles on the weld surface cannot be precisely controlled, easily damaging the weld surface morphology and creating new welding defects. Secondly, the slag removal lacks flexibility; different types of workpieces have different weld morphologies, and the steel needles can only roughly remove slag from a certain area, unable to act on all areas, resulting in a low slag removal rate. It is evident that existing technical solutions have limitations in slag removal efficiency and effectiveness, which affects welding efficiency and weld quality.

[0034] refer to Figure 1 This application provides a welding system suitable for workpieces having any one of a Y-groove, V-groove, and U-groove. The workpiece has an annular welding area and is rotatably positioned for welding the welding area during rotation. The welding system includes an impact gun 1, a displacement device 2, and a control assembly. The impact gun 1 is configured to strike the weld surface during welding to remove weld slag. The displacement device 2 is used to move the impact gun relative to the workpiece along the depth and width directions of the groove. The control assembly is used to control the movement of the displacement device 2 during welding to remove weld slag at different locations; the control assembly is configured to control the displacement device 2 to reciprocate along the width direction X. The control assembly is also configured to stop the displacement device 2 from moving along the depth direction Y when the impact head of the impact gun 1 touches the weld surface, and to control the displacement device 2 to move away from the weld surface along the depth direction Y during welding when the pressure between the impact head and the weld surface reaches a set condition.

[0035] In this embodiment, the welding system may also include a welding torch, with the welding torch and impact torch positioned at different locations within the annular welding area to reduce mutual interference. By controlling the rotation of the workpiece, welding can be completed throughout the entire circumference of the annular welding area, and the impact torch can simultaneously remove slag from the entire circumference of the annular weld. Before performing simultaneous welding and slag removal, this system requires completing an initial weld in the welding area, and then positioning the impact torch 1 onto the weld surface. After positioning the impact torch 1, simultaneous welding and slag removal operations can be performed.

[0036] When positioning the impact gun 1, the control component controls the displacement device 2 to move the impact gun 1 towards the weld surface along the depth direction Y. When the impact gun 1 touches the weld surface, the control component promptly stops the impact gun 1 from moving further, ensuring the impact head is just touching the weld surface. This ensures the effectiveness of slag removal. Then, the workpiece to be welded is rotated, and the welding gun and impact gun 1 work simultaneously. By controlling the displacement device 2 to reciprocate along the width direction X, slag removal is ensured on the entire weld surface. As the welding process progresses, the area to be welded is not completely filled, causing the weld surface to gradually compress the impact head. If the impact head is kept fixed in the depth direction Y, the compression between the impact head and the weld surface will intensify, posing a risk of damaging the weld surface. However, by using the control component to detect the compression state in real time and control the displacement device 2 to move away from the weld surface when the compression state reaches a set condition, the compression force between the impact head and the weld surface can be reduced in time, reducing the risk of excessive compression force damaging the weld and facilitating flexible slag removal.

[0037] In summary, the solution of this embodiment ensures that the impact head is in contact with the weld surface without excessive pressure during the welding process, achieving flexible and automated slag removal. This reduces damage to the weld surface during slag removal, thereby improving the slag removal effect and welding quality, while not affecting the welding process. It achieves simultaneous flexible slag removal and welding, improving processing efficiency. In some embodiments, the impact gun 1 is configured as an ultrasonic impact gun. The ultrasonic impact gun has an approximate cylindrical structure, with its axis extending along the depth direction Y. The impact head at its end is replaceable to adapt to different materials of the workpiece, allowing for better slag removal. For example, when the weld material is hard, an impact head with a diameter of less than 5mm is selected; when the weld material is soft, an impact head with a diameter of more than 6mm is selected.

[0038] In some embodiments, the plane containing the annular welding area is parallel to the plumb line, the depth direction Y of the bevel is consistent with the vertical direction, and the width direction X of the bevel is in the horizontal plane. The welding torch is set at the top of the annular welding area, and the impact torch is set at the bottom of the annular welding area. During the slag removal process, the welding slag can fall off automatically under the action of gravity, reducing the amount of removed welding slag remaining on the weld surface and interfering with the operation of the impact torch 1.

[0039] In some embodiments, the control component is further configured to adjust the amount of oscillation of the displacement device 2 in the width direction X according to the amount of displacement of the displacement device 2 in the depth direction Y when the displacement device 2 moves away from the weld surface in the depth direction Y.

[0040] In this embodiment, the distance from the center of the weld along the width direction X to one end of the weld is half the amount of oscillation. When the control device 1 controls the displacement device 2 to move away from the weld surface along the depth direction Y, it means that the molten pool has accumulated to a certain extent. Based on the characteristics of the cross-sectional shape of the bevel, the width of the weld surface will change as the molten pool accumulates. By adaptively adjusting the amount of oscillation of the displacement device 2 along the width direction X, it can be ensured that the impact head can fully clean the slag on the entire surface of the weld in the width direction X, thereby improving the slag cleaning effect.

[0041] In some embodiments, adjusting the swing amount of the displacement device 2 along the width direction Y based on the displacement amount of the displacement device 2 along the depth direction Y includes: increasing the swing amount of the displacement device 2 along the width direction X.

[0042] Specifically, for Y-shaped, V-shaped, and U-shaped bevels, the further away from the root of the bevel in the depth direction Y, the larger the bevel size in the width direction X. As welding progresses, gradually increasing the oscillation of the displacement device 2 in the width direction X allows the impact gun 1 to better adapt to changes in weld size, thereby fully cleaning slag from various positions on the weld surface and improving the slag removal effect.

[0043] In some embodiments, adjusting the swing amount of the displacement device 2 along the width direction X according to the displacement amount of the displacement device 2 along the depth direction Y includes: pre-constructing and storing the correspondence between the displacement amount of the displacement device 2 along the depth direction Y and the swing amount along the width direction X for each weld cross-section feature according to different weld cross-section features; retrieving the corresponding correspondence according to different workpieces to be welded; and controlling the movement of the displacement device 2 according to the correspondence during the welding process.

[0044] For example, Figure 5 This diagram illustrates the slag removal process for a workpiece with a V-groove. Initial welding is performed to form the initial weld A. The oscillation of the displacement device 2 along the width direction is set to L0. Then, simultaneous welding and slag removal are performed. As welding progresses, the weld gradually compresses the impact head until a set condition is reached. The control component controls the displacement device 2 to move away from the weld surface by a first distance H1 along the depth direction Y. Correspondingly, the control component increases the oscillation of the displacement device 2 along the width direction from L0 to L1. The value of L1 is obtained from H1 based on a pre-established correlation, and the value of L1 is approximately equal to the width of the groove at this position. Similarly, when the control device again controls the displacement device 2 to move away from the weld surface by a second distance H2 along the depth direction Y, the control component increases the oscillation of the displacement device 2 along the width direction from L1 to L2 (the value of L2 is approximately equal to the width of the groove at this position), until the groove welding is completed.

[0045] As can be seen, based on the solution of this embodiment, the oscillation amount of the displacement device 2 can be continuously adjusted as welding progresses, thereby comprehensively completing slag removal. The process of adjusting the displacement device 2 is executed by the control component, which can not only realize automated slag removal, but also ensure that the extrusion force between the impact head and the weld surface is always maintained within a stable range. This ensures that the slag removal force of the impact gun 1 is also relatively stable during the welding process, achieving a balanced slag removal effect. Moreover, by pre-constructing the comparison relationship of welds with different cross-sectional shapes, this welding system is applicable to various types of welds, improving its applicability.

[0046] It is worth noting that, based on different weld cross-sectional characteristics, the pre-constructed and stored relationship between the displacement of displacement device 2 along the depth direction Y and the oscillation along the width direction X for each weld cross-sectional characteristic refers to, still based on... Figure 5 Taking the bevel shown as an example, the cross-sectional shape of the bevel can be regarded as an isosceles triangle. At different heights of the isosceles triangle, according to trigonometric functions, the ratio of the different heights of the isosceles triangle to the width corresponding to that height is a fixed value. This ratio is only related to the base angles of the isosceles triangle. Therefore, for welds with a shape approximately equal to an isosceles triangle, a correlation between the height and width corresponding to isosceles triangles with different base angles can be constructed based on trigonometric functions. When removing slag, after selecting the corresponding correlation, the displacement device is controlled to move away from the weld along the depth direction Y by a certain distance. Then, the swing amount of the displacement device 2 along the width direction X can be adjusted according to the correlation. The adjusted swing amount can better match the width of the weld surface at this position, thereby improving slag removal.

[0047] Of course, the correspondence between different cross-sectional shapes can also be stored in the controller in the form of a functional relationship. When adjusting the swing amount, the control component calculates and obtains the corresponding swing amount based on the displacement of the displacement device 2 along the depth direction Y and the functional relationship.

[0048] In some embodiments, the displacement device 2 moves away from the weld surface along the depth direction Y by a fixed value each time; that is, in the aforementioned embodiments, L1 is equal to L2. This configuration facilitates control of the displacement device 2, ensuring that the contact force between the impact head and the weld surface is almost equal each time the device moves away from the weld and a new round of slag removal begins, thereby ensuring a balanced slag removal effect throughout the welding process.

[0049] refer to Figure 2In some embodiments, the welding system further includes a base 3 and an elastic element 4. The base 3 is connected to the displacement device 2. One end of the elastic element 4 is connected to the base 3, and the other end of the elastic element 4 is connected to the impact gun 1. Controlling the displacement device 2 to stop moving along the depth direction Y when it drives the impact gun 1 to move along the depth direction Y to the point where the impact head of the impact gun 1 touches the weld surface includes: when the displacement device 2 drives the base 3 to move along the depth direction Y to the point where the impact head touches the weld surface and the elastic element 4 is compressed to a first compression amount, the control component controls the displacement device 2 to stop moving along the depth direction Y.

[0050] Specifically, the base 3 serves to support the impact gun 1 and drive its movement. The displacement device 2 moves the impact gun 1 relative to the bevel by moving the base 3. The base 3 improves the stability of the impact gun 1's movement. The impact gun 1 is movable relative to the base 3 along the depth direction Y via the elastic element 4. As the base 3 drives the impact gun 1 towards the initial weld A, when the impact head of the impact gun 1 touches the weld, the impact gun 1 will be restricted by the weld and will not continue to move along the depth direction Y. The displacement device 2 will then drive the base 3 to continue moving towards the weld along the depth direction Y. This causes the elastic element 4 to compress. The compression of the elastic element 4 reflects both the contact between the impact head and the weld surface and the compression state between the impact head and the weld surface. The greater the compression, the more severe the compression state, or the more severe the compression force, between the impact head and the weld surface.

[0051] By setting the elastic element 4 and detecting its compression, the magnitude of the extrusion force between the impact head and the weld can be obtained more intuitively. In particular, using whether the compression of the elastic element 4 reaches the first compression amount as the judgment condition mentioned above can reduce the risk of damage to the weld surface during the positioning impact gun 1 process. Therefore, the solution of this embodiment can achieve flexible slag removal in a simple, efficient and reliable manner. On the other hand, when the impact head moves to a position where the weld height changes, such as a pit or depression in the weld, the elastic element 4 can ensure that the impact head can still maintain close contact with the weld surface, thereby improving the slag removal effect and welding quality.

[0052] It is worth noting that the first compression amount should be set to a small value to reflect the state in which the impact head is just touching the surface of the initial weld A and there is only a small extrusion force between them. If the first compression amount is too large, it means that when positioning the impact head, the control component will only stop the base 3 from moving when the extrusion force between the impact head and the surface of the initial weld A reaches a large value, which may easily damage the surface of the initial weld A.

[0053] In some embodiments, the elastic element 4 is a spring. The compression direction of the spring is consistent with the depth direction Y, and the two ends of the spring are connected to the impact gun 1 and the base 3, respectively.

[0054] In some embodiments, the welding system includes multiple springs distributed circumferentially around the base 3, and the impact gun 1 is connected to the multiple springs. By providing multiple springs, the stability of the impact gun 1 can be improved, ensuring that the impact gun 1 moves relative to the base 3 in the depth direction Y when the impact head is squeezed by the weld surface, and reducing the movement of the impact gun 1 relative to the base 3 in other directions.

[0055] In some embodiments, when the extrusion state between the impact head and the weld surface reaches a set condition during the welding process, controlling the displacement device 2 to move away from the weld surface in the depth direction Y includes: when the extrusion force between the impact head and the weld surface increases to the point that the elastic element 4 is compressed to a second compression amount, controlling the displacement device 2 to drive the base 3 away from the weld surface in the depth direction Y.

[0056] Specifically, when the displacement control device 2 moves away from the weld surface along the depth direction Y, the impact head also tends to move away from the weld surface. However, under the action of the elastic element 4, the impact head will remain in contact with the weld surface. During this process, the compression of the elastic element 4 gradually decreases, and the elastic force received by the impact gun 1 from the elastic element 4 gradually decreases. In other words, the extrusion pressure between the impact head and the weld surface gradually decreases, thereby releasing the pressure between the impact head and the weld surface and reducing the damage to the weld by the impact gun 1.

[0057] Advantageously, the second compression amount should be greater than the first compression amount, but the value of the second compression amount should not be too large. The second compression amount is used to reflect the thickness of the molten pool accumulation during the welding process. As the welding process proceeds, the molten pool continuously accumulates, causing the impact head to be continuously squeezed. During the squeezing of the impact head, the displacement device 2 remains fixed along the depth direction Y. Therefore, the base 3 is also fixed along the depth direction Y, so the elastic element 4 is gradually compressed. When the compression amount of the elastic element 4 gradually increases to the second compression amount, the displacement device 2 is promptly controlled to move the base 3 away from the weld, reserving space for the subsequent formation of the molten pool and improving the sustainability of simultaneous welding and simultaneous slag removal. In some embodiments, the value of the second compression amount can be adjusted according to the hardness of the weld and slag. For example, when the weld and slag are relatively hard, the second compression amount can be set to a relatively large value to ensure the slag removal force. When the weld and slag are relatively soft, the second compression amount can be set to a relatively small value to prevent damage to the weld.

[0058] In some embodiments, controlling the displacement device 2 to move away from the weld surface along the depth direction Y includes: controlling the displacement device 2 to move the base 3 along the depth direction Y until the compression amount of the elastic member 4 decreases from a second compression amount to a third compression amount.

[0059] Specifically, the third compression amount is set to a value slightly greater than zero. When the control displacement device 2 drives the base 3 away from the weld along the depth direction Y, the compression amount of the elastic element 4 is reduced from the relatively large second compression amount to the relatively small third compression amount. This indicates that the extrusion pressure between the impact head and the weld surface has been basically released, and the impact head is in a state of just contacting the weld surface, similar to the state when the impact head is initially positioned on the surface of the initial weld A. In this way, the time loss caused by the impact head detaching from the weld surface and repositioning can be avoided.

[0060] In some embodiments, the third compression amount is equal to the first compression amount.

[0061] In some embodiments, the control component includes a controller and a sensor. The sensor is used to detect the amount of compression of the elastic element 4. The controller is used to control the motion state of the displacement device 2 based on the amount of compression.

[0062] Specifically, by setting up sensors, the compression of the elastic element 4 can be accurately detected, thereby improving control accuracy and making it more conducive to achieving flexible slag removal.

[0063] refer to Figure 3 In some embodiments, the sensor includes a photoelectric switch 5. The control assembly also includes a trigger plate 6. The photoelectric switch 5 is fixedly disposed relative to the base 3. The trigger plate 6 is fixedly disposed relative to the impact gun 1. The trigger plate 6 is configured to move relative to the photoelectric switch 5 along the depth direction Y to switch the on / off state of the optical path of the photoelectric switch 5 to trigger a control signal, and the controller controls the displacement device 2 to operate according to the control signal.

[0064] Specifically, the photoelectric switch has a transmitter for emitting light signals and a receiver for receiving light signals. When the displacement device 2 moves the base 3, the trigger plate moves relative to the photoelectric switch, so that the trigger plate 6 can cut off the light path when it moves to a specific position. Therefore, the trigger plate 6 can be used to change the on / off state of the light path, thereby sending different control signals to control the action of the displacement device 2.

[0065] Still referencing Figure 3In some embodiments, the photoelectric switch 5 includes a first photoelectric switch 51 and a second photoelectric switch 52. The trigger piece has a first blocking portion 61 and a second blocking portion 62. The first blocking portion 61 and the second blocking portion 62 are spaced apart in the depth direction Y. When the displacement device 2 moves the base 3 along the depth direction Y until the top of the impact head touches the weld surface, the second blocking portion 62 is located outside the U-shaped groove of the second photoelectric switch 52, and the first blocking portion 61 moves into the U-shaped groove of the first photoelectric switch 51. The light path of the first photoelectric switch 51 is blocked and a first control signal is triggered. The controller controls the displacement device 2 to stop moving along the depth direction Y according to the first control signal. During the welding process, when the impact head is squeezed between the impact head and the weld surface until the second blocking portion 62 moves into the U-shaped groove of the second photoelectric switch 52, the light path of the second photoelectric switch 52 is blocked and a second control signal is triggered. The controller controls the displacement device 2 to move the base 3 away from the weld surface along the depth direction Y according to the second control signal.

[0066] Specifically, in this embodiment, the transmitter and receiver are respectively disposed on two opposite sidewalls of the U-shaped groove. When the optical path is connected, the first photoelectric switch 51 and the second photoelectric switch 52 do not issue control signals. During the positioning of the impact gun 1, when the top of the impact head touches the weld surface and the base 3 continues to move towards the weld, the elastic element 4 is compressed, and the first blocking part 61 of the trigger piece 6 moves into the U-shaped groove of the first photoelectric switch 51 and blocks the optical path. The first photoelectric switch 51 issues the first control signal.

[0067] When the impact head has not yet touched the weld, the first shielding part 61 is closer to the weld in the depth direction Y relative to the U-shaped groove of the first photoelectric switch 51, and the distance between the first shielding part 61 and the U-shaped groove of the first photoelectric switch 51 in the depth direction Y can be slightly less than or equal to the first compression amount. Thus, during the positioning of the impact gun 1, when the compression amount of the elastic element 4 reaches the first compression amount, the first shielding part 61 moves into the U-shaped groove of the first photoelectric switch 51 to block the light path and trigger the first control signal; the second photoelectric switch 52 is farther away from the first photoelectric switch 51 in the depth direction Y. The second shielding part 62 is farther away from the weld in the depth direction Y relative to the first shielding part 61. When the impact head does not touch the weld, the second shielding part 62 is closer to the weld in the depth direction Y relative to the U-shaped groove of the second photoelectric switch 52. The distance between the second shielding part 62 and the U-shaped groove of the second photoelectric switch 52 in the depth direction Y can be slightly less than or equal to the second compression amount. In this way, during the welding process, when the compression amount of the elastic element 4 increases to the second compression amount, the second shielding part 62 moves into the U-shaped groove of the second photoelectric switch 52 to block the light path and trigger the second control signal.

[0068] It is worth noting that the first blocking part 61 should have a certain size in the depth direction Y to ensure that when the elastic element 4 is compressed to a larger second compression amount, the first blocking part 61 is still partially in the U-shaped groove of the first photoelectric switch 51 so as to keep the light path of the first photoelectric switch 51 always in the open state.

[0069] Advantageously, in order to achieve the above effects, refer to Figure 4 The trigger piece 6 includes a base portion and a protrusion. The protrusion extends from the edge of the base portion relative to the base portion along the width direction X, and the dimension of the protrusion in the depth direction Y is smaller than the dimension of the base portion in the depth direction Y, making the trigger piece 6 a structure with a stepped surface. The protrusion serves as a first blocking portion 61, and the base portion serves as a second blocking portion 62.

[0070] In some embodiments, the sensor may also be a laser displacement sensor, a capacitive displacement sensor, a magnetostrictive displacement sensor, or other types of sensors.

[0071] In some embodiments, the output power of the impact gun 1 is adjustable. The control component is configured to control the impact gun 1 to operate at a first power during welding to remove weld slag, and to control the impact gun 1 to operate at a second power after welding to remove residual stress in the weld, the second power being greater than the first power.

[0072] In this embodiment, the slag removal mechanism is also used as a residual stress removal mechanism, eliminating the need for an additional residual stress removal mechanism. This simplifies the number of system components, reduces costs, and allows for residual stress removal simply by adjusting the power of the impact gun 1 after welding, thus improving processing efficiency.

[0073] In some embodiments, during slag removal, the output power of the impact gun 1 is set to 30% to 70% of its maximum output power, preferably 50%. At this setting, the impact head can dislodge the weld slag without creating pits in the weld. During residual stress removal, the output power of the impact gun 1 is set to 70% to 100% of its maximum output power, preferably 85%. At this setting, the impact head can create pits on the weld surface, forming compressive stress and achieving the best stress relief effect. (Reference) Figure 2 In some embodiments, the displacement device 2 includes a first translation mechanism 21 and a second translation mechanism 22. The second translation mechanism 22 is disposed on the first translation mechanism 21. The impact gun 1 is connected to the second translation mechanism 22. The first translation mechanism 21 is used to drive the impact gun 1 to move along the width direction X. The second translation mechanism 22 is used to drive the impact gun 1 to move along the depth direction Y.

[0074] Specifically, the depth direction Y of the bevel is consistent with the vertical direction, and the width direction X is in the horizontal plane. The first translation mechanism 21 is a horizontal servo module, and the second translation mechanism 22 is a lifting servo module. The base 3 and the photoelectric switch are both connected to the second translation mechanism 22. The first translation mechanism 21 is used to drive the second translation mechanism 22 to move in the horizontal plane, especially along the width direction X of the bevel. The second translation mechanism 22 is used to drive the base 3 and the photoelectric switch to move in the vertical direction. When the impact head does not touch the weld, the impact gun 1 and the photoelectric switch will not have relative displacement in the vertical direction. When the impact head touches the weld and compresses the elastic element 4, the impact gun 1 and the photoelectric switch will have relative displacement in the vertical direction.

[0075] Based on the scheme of this embodiment, setting the displacement device 2 as a servo module can achieve precise adjustment of the position of the base 3 and has strong controllability, which is conducive to achieving flexible slag removal and thus improving welding quality. In other embodiments, the displacement device 2 is a robot, which directly drives the base 3 to move.

[0076] refer to Figure 2 In some embodiments, the welding system further includes a weld seam positioning system 7. The weld seam positioning system consists of a laser displacement sensor, an industrial computer, and a PLC control system. The function of the weld seam positioning system 7 is to, after the workpiece is loaded, use a transverse servo module (first translation mechanism 21) to move the laser displacement sensor along the width direction X to locate the weld seam morphology on the workpiece surface, thereby ensuring that the impact gun 1 is positioned directly below the weld seam and that the head of the impact gun 1 is aligned with the center of the weld seam. Alternatively, the worker can manually operate the transverse servo module to control the position of the impact gun to align with the center of the weld seam.

[0077] refer to Figure 1 In some embodiments, the welding system further includes a welding positioner 8, which is used to clamp the workpiece to be welded and drive the workpiece to be welded to rotate.

[0078] The workflow of the welding system described in this application is briefly described below.

[0079] 1. Weld seam information input: The worker inputs the moving distance of the lifting servo module as values ​​such as H1, H2, H3 into the controller according to the weld seam information in the drawing. The controller obtains the swing amount L1, L2, L3 of the lateral servo module according to the input moving distance.

[0080] 2. Workpiece loading: The cylindrical workpiece is clamped onto the welding positioner by manual labor or a robotic arm.

[0081] 3. Weld seam location: The worker operates the equipment to identify the weld seam position, ensuring that the head of the ultrasonic impact gun is directly facing the center of the weld seam.

[0082] 4. Ultrasonic impact gun contacts the weld: The worker operates the equipment to make the lifting servo drive the ultrasonic impact gun to rise and contact the weld. When the first photoelectric switch 51 is triggered, the ultrasonic impact gun stops rising.

[0083] 5. Ultrasonic impact gun power setting: The power of the ultrasonic impact gun is set to 30%-70% of the total power by manual or automatic control program to achieve the level of slag removal without damaging the weld.

[0084] 6. Welding: The welding positioner starts to rotate, the welding torch welds at the top of the circumferential weld, the slag removal system cleans the slag at the bottom of the circumferential weld, and the ultrasonic impact gun reciprocates according to the H and L values ​​set in the control system, so that all positions between the weld layers are affected. The weld slag falls downward due to gravity.

[0085] 7. Ultrasonic stress relief: When welding is finished, the power of the ultrasonic impact gun is set to 80%-100% of the total power by manual or automatic control program. The welding positioner continues to drive the workpiece to rotate, and the ultrasonic impact gun performs ultrasonic stress relief operation on the weld.

[0086] 8. Workpiece unloading: The cylindrical workpiece is unloaded from the welding positioner by manual labor or a robot and then proceeds to the next process.

[0087] Based on the embodiments disclosed above, in the absence of explicit denial or conflict, the technical features of one embodiment may be advantageously combined with one or more other embodiments.

[0088] This document uses specific embodiments to illustrate the principles and implementation methods of this disclosure. The descriptions of the embodiments above are only for the purpose of helping to understand the methods and core ideas of this disclosure. It should be noted that those skilled in the art can make various improvements and modifications to this disclosure without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this disclosure.

Claims

1. A welding system, characterized in that, Suitable for workpieces having any one of Y-groove, V-groove, and U-groove bevels, the workpiece having an annular welding area, the workpiece being rotatably positioned for welding the welding area during rotation, the welding system comprising: The impact gun (1) is configured to strike the weld surface during the welding process to remove weld slag; Displacement device (2) is used to move the impact gun relative to the workpiece to be welded along the depth and width directions of the bevel; and A control component is configured to control the movement of the displacement device (2) during welding to remove the weld slag at different locations. The control component is configured to control the displacement device (2) to reciprocate along the width direction (X). The control component is also configured to control the displacement device (2) to stop moving along the depth direction (Y) when the displacement device (2) moves the impact gun (1) along the depth direction (Y) to the point where the impact head at the end of the impact gun (1) touches the weld surface. The control component is also configured to control the displacement device (2) to move away from the weld surface along the depth direction (Y) when the pressure between the impact head and the weld surface reaches a set condition during welding.

2. The welding system according to claim 1, characterized in that, The control component is also configured to adjust the amount of oscillation of the displacement device (2) along the width direction (X) based on the amount of displacement of the displacement device (2) along the depth direction (Y) when controlling the displacement device (2) to move away from the weld surface along the depth direction (Y).

3. The welding system according to claim 2, characterized in that, Adjusting the amount of oscillation of the displacement device (2) along the width direction (Y) based on the amount of displacement of the displacement device (2) along the depth direction (Y) includes: increasing the amount of oscillation of the displacement device (2) along the width direction (X).

4. The welding system according to claim 2, characterized in that, Adjusting the oscillation amount of the displacement device (2) along the width direction (X) based on the displacement amount of the displacement device (2) along the depth direction (Y) and the oscillation amount along the width direction (X) for each weld cross-section feature is pre-constructed and stored, and the corresponding correlation relationship is retrieved according to different weld parts and the displacement device (2) is controlled to move according to the correlation relationship during the welding process.

5. The welding system according to claim 1, characterized in that, It also includes a base (3) and an elastic element (4), the base (3) being connected to the displacement device (2), one end of the elastic element (4) being connected to the base (3), and the other end of the elastic element (4) being connected to the impact gun (1). Controlling the displacement device (2) to stop moving along the depth direction (Y) when the displacement device (2) drives the impact gun (1) to move along the depth direction (Y) until the impact head of the impact gun (1) touches the weld surface includes: when the displacement device (2) drives the base (3) to move along the depth direction (Y) until the impact head touches the weld surface and the elastic element (4) is compressed to a first compression amount, the control component controls the displacement device (2) to stop moving along the depth direction (Y).

6. The welding system according to claim 1, characterized in that, It also includes a base (3) and an elastic element (4), the base (3) being connected to the displacement device (2), one end of the elastic element (4) being connected to the base (3), and the other end of the elastic element (4) being connected to the impact gun (1). When the extrusion state between the impact head and the weld surface reaches a set condition during the welding process, controlling the displacement device (2) to move away from the weld surface along the depth direction (Y) includes: when the extrusion pressure between the impact head and the weld surface increases to the point that the elastic element (4) is compressed to a second compression amount, controlling the displacement device (2) to drive the base (3) away from the weld surface along the depth direction (Y).

7. The welding system according to claim 6, characterized in that, Controlling the displacement device (2) to move away from the weld surface along the depth direction (Y) includes: controlling the displacement device (2) to move the base (3) along the depth direction (Y) until the compression of the elastic member (4) decreases from the second compression to the third compression.

8. The welding system according to any one of claims 5 to 7, characterized in that, The control component includes a controller and a sensor, the sensor being used to detect the compression of the elastic element (4), and the controller being used to control the motion state of the displacement device (2) based on the compression.

9. The welding system according to claim 8, characterized in that, The sensor includes a photoelectric switch (5), and the control component also includes a trigger plate (6). The photoelectric switch (5) is fixedly disposed relative to the base (3), and the trigger plate (6) is fixedly disposed relative to the impact gun (1). The trigger plate (6) is configured to move relative to the photoelectric switch (5) along the depth direction (Y) to switch the on / off state of the optical path of the photoelectric switch (5) to trigger a control signal. The controller controls the displacement device (2) to operate according to the control signal.

10. The welding system according to claim 9, characterized in that, The photoelectric switch (5) includes a first photoelectric switch (51) and a second photoelectric switch (52). The trigger plate has a first blocking portion (61) and a second blocking portion (62). The first blocking portion (61) and the second blocking portion (62) are spaced apart in the depth direction (Y). When the displacement device (2) drives the base (3) to move along the depth direction (Y) until the impact head touches the weld surface, the second shielding part (62) is located outside the U-shaped groove of the second photoelectric switch (52), and the first shielding part (61) moves into the U-shaped groove of the first photoelectric switch (51). The light path of the first photoelectric switch (51) is blocked and a first control signal is triggered. The controller controls the displacement device (2) to stop moving along the depth direction (Y) according to the first control signal. During the welding process, when the impact head is pressed between the weld surface and the second shielding part (62) moves into the U-shaped groove of the second photoelectric switch (52), the light path of the second photoelectric switch (52) is blocked and a second control signal is triggered. The controller controls the displacement device (2) to drive the base (3) away from the weld surface along the depth direction (Y) according to the second control signal.

11. The welding system according to any one of claims 1 to 7, characterized in that, The output power of the impact gun (1) is adjustable, and the control component is configured to control the impact gun (1) to operate at a first power to remove weld slag during the welding process, and to control the impact gun (1) to operate at a second power to remove residual stress in the weld after welding is completed, wherein the second power is greater than the first power.

12. The welding system according to any one of claims 1 to 7, characterized in that, The displacement device (2) includes a first translation mechanism (21) and a second translation mechanism (22). The second translation mechanism (22) is disposed on the first translation mechanism (21). The impact gun (1) is connected to the second translation mechanism (22). The first translation mechanism (21) is used to drive the impact gun (1) to move along the width direction (X). The second translation mechanism (22) is used to drive the impact gun (1) to move along the depth direction (Y).

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