Pipe fitting welding seam alignment adjustment system and method and closed-loop system
By using a closed-loop control system for pipe fitting weld alignment and adjustment, the problems of low efficiency and unstable welding quality caused by manual operation are solved, achieving automated and efficient pipe fitting alignment and adjustment, and reducing the risk of product damage.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-03-02
- Publication Date
- 2026-03-31
AI Technical Summary
In the existing technology, manual operation before pipe welding is inefficient, slow in inspection, and has a small inspection range, which affects the welding quality. Furthermore, excessive tension may cause damage to tooling fixtures and weld cracking.
The pipe fitting weld alignment and adjustment system includes a mounting base, tooling support device, alignment and tightening actuator, alignment parameter detection device and system controller. It achieves automated alignment and adjustment through closed-loop control, and detects and feeds back the tightening force in real time to ensure that the qualified standard is met.
It improves the efficiency and quality of pipe fitting weld alignment, reduces the risk of product damage due to excessive tension, and achieves fully automated operation without manual intervention.
Smart Images
Figure CN121756006A_ABST
Abstract
Description
Technical Field
[0001] This application belongs to the technical field of pipe fitting weld alignment, specifically relating to a pipe fitting weld alignment adjustment system, method, and closed-loop system. Background Technology
[0002] Currently, for pipe fittings made of two different materials with similar diameters, manual tooling and fixtures are used to tighten and fix the pipe fittings inside before welding, so that the two pipe fittings are approximately concentric before welding.
[0003] The tooling is tightened manually using wrenches, with repeated tightening based on experience. Feeler gauges and dial indicators are used to measure the joint gap and height difference. This process results in low production efficiency, slow inspection speed, and a small inspection range, negatively impacting product welding quality.
[0004] Furthermore, applying excessive force to the tooling fixture will reduce the service life of the gears within the fixture. During welding, due to the high temperature fusing two materials, excessive tension can cause deformation of the workpiece or weld cracking. Summary of the Invention
[0005] The purpose of this application is to provide a pipe fitting weld alignment adjustment system, method and closed-loop system to improve the efficiency and quality of pipe fitting weld alignment and reduce the risk of product damage due to excessive tension force.
[0006] To achieve the above objectives, the technical solution provided in this application is as follows: A pipe fitting weld alignment and adjustment system includes a mounting base, a tooling support device, an alignment and tightening actuator, an alignment parameter detection device, and a system controller. The alignment and tightening actuator includes at least one tightening output end for applying a tightening force to the tightening input end of the alignment tooling. The alignment parameter detection device is configured to detect the alignment geometric parameters at the pipe fitting joint on the alignment tooling in real time as the alignment tooling rotates to synchronously rotate the pipe fitting. The system controller is communicatively connected to the alignment and tightening actuator and the alignment parameter detection device. The process involves: receiving real-time alignment geometric parameters from the alignment parameter detection device; determining whether the current alignment state meets the qualification standard based on the real-time alignment geometric parameters; if the qualification standard is not met, controlling the alignment tightening actuator to continue tightening the alignment tooling's tightening input end according to the analysis results of the real-time alignment geometric parameters; after continuing tightening, re-acquiring the alignment geometric parameters and re-judging until a preset termination condition is met; the termination condition includes at least one of the following: the alignment state is qualified or the tightening force applied by the alignment tightening actuator reaches a safety threshold.
[0007] The beneficial effects of this application are: This application encapsulates the entire process of "detection-judgment-execution-re-inspection" into an automatic iterative cycle through the system controller. After one start, the system runs autonomously until the alignment is qualified or the safety threshold is triggered. No manual intervention is required throughout the process, which improves the alignment quality and efficiency of pipe fittings and reduces the risk of product damage due to excessive tension force. Attached Figure Description
[0008] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein: Figure 1 This is a three-dimensional structural schematic diagram of the pipe fitting weld alignment adjustment system provided in the embodiments of this application; Figure 2 yes Figure 1 A three-dimensional structural diagram of the mounting base in the pipe fitting weld alignment adjustment system; Figure 3 yes Figure 1 A three-dimensional structural diagram of a portion of the tooling bearing device in the pipe fitting weld alignment adjustment system; Figure 4 This is a three-dimensional schematic diagram of the assembly structure of the tooling in this application; Figure 5 yes Figure 4 A three-dimensional exploded view of the centering tooling; Figure 6 yes Figure 4 and Figure 5 A three-dimensional exploded view of the tensioning mechanism in the centering tooling; Figure 7 yes Figure 1 A three-dimensional structural diagram of one of the centering and tightening actuators and the rotary drive mechanism in the pipe fitting weld alignment and adjustment system; Figure 8 yes Figure 1 A three-dimensional structural diagram of another centering and tightening actuator in the pipe fitting weld alignment adjustment system; Figure 9 yes Figure 1 A three-dimensional structural diagram of the rotary drive mechanism in the pipe fitting weld alignment adjustment system; Figure 10 yes Figure 1 A three-dimensional structural diagram of the alignment parameter detection device in the pipe fitting weld alignment adjustment system; Figure 11 This is a flowchart of the pipe fitting weld alignment adjustment method provided in the embodiments of this application.
[0009] Explanation of reference numerals in the attached figures: Mounting base 10 Tooling bearing device 20 Tooling support platform 21 Carrying linear drive module 22 Tightening actuator 30 Tighten the output end 301 First centering tightening actuator 30A Second centering tightening actuator 30B Tightening linear drive module 31 Tightening mechanism 32 Translation base 321 Tightening component 322 Tightening drive motor 3221 Tightening shaft 3222 Alignment parameter detection device 40 Detection of linear drive module 41 Camera bracket 42 Line scan camera 43 Rotary drive mechanism 50 Rotary drive motor 51 Rotary drive shaft 52 60 tooling for medium Tighten input terminal 601 Central shaft 61 Tightening institutions 62 Multi-jaw chuck 621 622-ring array of tensioning blocks Large Gear 623 Transmission rod 624 Small Gear 625 First clamping plate 63 Clamping component 631 Second clamping plate 64 Detailed Implementation
[0010] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.
[0011] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.
[0012] Please see Figure 1 , Figure 1 This is a three-dimensional structural diagram of the pipe fitting weld alignment and adjustment system provided in this application embodiment. The pipe fitting weld alignment and adjustment system provided in this application is used for aligning materials (supporting and fixing the aligned tooling of the installed pipe fitting to be aligned; the structure of the aligned tooling can be referenced but is not limited to). Figure 4 The alignment adjustment system for pipe fitting welds provided in this application includes an installation base 10, a tooling bearing device 20, an alignment tightening actuator 30, an alignment parameter detection device 40, and a system controller.
[0013] Please see Figure 2 , Figure 2 yes Figure 1 This is a three-dimensional structural diagram of the mounting base 10 in the pipe fitting weld alignment and adjustment system. The mounting base 10 is the installation platform for the entire system. The tooling support device 20, the alignment and tightening actuator 30, the alignment parameter detection device 40, and the system controller are all fixed on the mounting base 10. The tooling support device 20, the alignment and tightening actuator 30, and the alignment parameter detection device 40 can be installed on the support panel at the top of the mounting base 10, and the system controller can be installed in the control cabinet below the support panel. The main body of the mounting base 10 can be a square steel frame with a cold-rolled steel plate support panel.
[0014] Please see Figure 1 and Figure 3 , Figure 3 yes Figure 1 This is a three-dimensional structural diagram of a portion of the tooling support device 20 in the pipe fitting weld alignment adjustment system. The tooling support device 20 is mounted on the mounting base 10 and is used to support and fix the alignment tooling that has been installed and is to be aligned onto the pipe fitting. In a further embodiment, the tooling support device 20 may include a linear drive module 22 and a tooling support platform 21. Figure 3 The structure of the tooling support platform 21 is shown. The support linear drive module 22 is mounted on the mounting base 10 and is used to drive the tooling support platform 21 to move in the horizontal direction to facilitate manual loading and unloading of materials. Specifically, the support linear drive module 22 can adopt a screw-slider mechanism. The tooling support platform 21 is fixedly connected to the slider of the support linear drive module 22. The screw-slider mechanism is powered by a servo motor. The support linear drive module 22 drives the tooling support platform 21 to move in a direction perpendicular to the axis of the pipe, so that the centering tool carrying the pipe can move between the working position and the loading and unloading position.
[0015] The structure of the alignment tooling and the basic principles and operation process of aligning pipe fitting welds are described below to better understand the role of the pipe fitting weld alignment adjustment system of this application in pipe fitting weld alignment.
[0016] Please see Figure 4 and Figure 5 , Figure 4 This is a three-dimensional schematic diagram of the assembly structure of the tooling in this application. Figure 5 yes Figure 4 The exploded three-dimensional diagram of the centering fixture 60 shows that the centering fixture 60 includes a central shaft 61 and at least one tensioning mechanism 62, which corresponds to the butt weld of the pipe fittings. The central shaft 61 serves as a reference support module, running the entire length of the centering fixture 60, and acts as the installation and rotation reference for all moving parts. The tensioning mechanism 62 receives power input (for example, the torque output end 301 of the centering torque actuator 30 in the pipe fitting weld alignment adjustment system of this application outputs power to the tensioning mechanism 62), and after transmission conversion, outputs tensioning force to the inner wall of the pipe fitting at the butt weld, thereby achieving centering of the two pipe fittings.
[0017] Please see Figure 6 , Figure 6 yes Figure 4 and Figure 5 An exploded three-dimensional schematic diagram of the tensioning mechanism 62 in the centering fixture 60. In some specific embodiments, the tensioning mechanism 62 includes a multi-jaw chuck 621 passing through the central shaft 61, a ring array of tensioning blocks 622, and a large gear 623, as well as at least one transmission rod 624 located radially outside the central shaft 61, and a small gear 625 fixed to one end of the transmission rod 624; each small gear 625 meshes with the large gear 623 respectively, so that the synchronous rotation of each small gear 625 drives the large gear 623 to rotate; the multi-jaw chuck 621 and the large gear 623 are connected by transmission, the chuck body of the multi-jaw chuck 621 is fixedly sleeved on the central shaft 61, each jaw of the multi-jaw chuck 621 can move radially relative to the chuck body, and the number of jaws of the multi-jaw chuck 621 can be three, six, or other numbers. Figure 6(The diagram shows the case where the multi-jaw chuck 621 has six jaws). The large gear 623 is movably sleeved on the central shaft 61 and can rotate relative to the central shaft 61. Through the transmission connection between the multi-jaw chuck 621 and the large gear 623, the rotation of the large gear 623 drives the synchronous radial movement of each jaw of the multi-jaw chuck 621. The annular array 622 of tensioning blocks includes multiple tensioning blocks, the number of which is the same as the number of jaws of the multi-jaw chuck 621, so that the tensioning blocks are connected to the jaws one by one. The multiple tensioning blocks are used to directly contact the inner wall of the pipe to apply tensioning force. The other end of the transmission rod 624 extends out of the annular array 622 of tensioning blocks and serves as a torque input end 601. External force (e.g., the torque output ends 301 of the alignment torque actuator 30 in the pipe fitting weld alignment adjustment system of this application) drives each transmission rod 624 to rotate, synchronously driving the small gears 625 on each transmission rod 624 to rotate, thereby driving the large gear 623 to rotate. The rotation of the large gear 623 drives each jaw on the multi-jaw chuck 621 to extend radially along the multi-jaw chuck 621, thereby pushing each tensioning block to extend radially along the multi-jaw chuck 621, achieving tensioning of the inner wall of the pipe fitting. The number of transmission rods 624 and their corresponding small gears 625 can be one or multiple, for example... Figure 6 The two or more transmission rods 624 shown are arranged circumferentially along the central shaft 61 to improve the rotational smoothness of the large gear 623 through the rotation of multiple small gears 625.
[0018] The transmission path of the tensioning mechanism 62 in this application can be summarized into the following stages: Power input stage: (Through each torque output end 301 of the centering torque actuator 30 described below) a rotational torque is applied to each transmission rod 624, the transmission rod 624 rotates around its own axis, and the pinion 625 fixedly connected to its end rotates synchronously.
[0019] First stage of transmission: each pinion 625 meshes with the large gear 623, and the rotation of the pinion 625 drives the large gear 623 to rotate around the axis of the central shaft 61.
[0020] Secondary transmission and motion conversion stage: The large gear 623 rotates, driving the transmission elements on the multi-jaw chuck 621 to move (such as: six circumferentially distributed small bevel gears, six radial lead screws, or six sets of rack mechanisms), converting the circumferential rotation of the large gear 623 into the linear extension and retraction motion of the six jaws along the radial direction of the chuck body.
[0021] Output phase: The six jaws extend radially synchronously and at the same speed. A tensioning block is fixedly installed at the end of each jaw. The outer surface of the tensioning block contacts the inner wall of the pipe fitting and applies uniform radial pressure until the axis of the centering fixture 60 is forcibly aligned with the axis of the pipe fitting.
[0022] After centering is completed: the entire centering fixture 60 forms a rigid whole with the pipe to be centered, and the two pipes on both sides of the weld are forced back to the same reference axis by their respective tensioning forces, thus achieving weld alignment.
[0023] In a further embodiment, the centering fixture 60 also includes a gap adjustment mechanism for adjusting the mating gap between the two pipe fittings after the centering fixture 60 is inserted into the pipe fitting. The mating gap here refers to the size of the mating gap between the two pipe fittings along the axial direction of the pipe fitting. Specifically, the gap adjustment mechanism includes a first pressing plate 63 and a second pressing plate 64 passing through the central shaft 61. The first pressing plate 63 and the second pressing plate 64 are respectively located on both sides of the tensioning mechanism 62. The first pressing plate 63 and the second pressing plate 64 are used to abut against the two ends of the pipe fitting to be mated. One of the first pressing plate 63 and the second pressing plate 64 is provided with a pressing element 631. For example, the first pressing plate 63 is provided with a pressing element 631. By moving the pressing element 631 relative to the first pressing plate 63 (the movement of the first pressing plate 63 includes at least a component along the axial direction parallel to the pipe fitting), the pressing element 631 pushes the end of the pipe fitting to move, thereby reducing the mating gap to meet the welding requirements. There can be one clamping element 631; or there can be multiple clamping elements 631, with multiple clamping elements 631 arranged circumferentially along the central shaft 61, so that when adjusting the pipe fitting gap, the axial movement of one pipe fitting on the weld side is more stable. The driving mechanism that drives the clamping element 631 to move axially along the pipe fitting can be arbitrary. For example, it can be driven by each torque output end 301 of the centering torque actuator 30 in the pipe fitting weld alignment adjustment system of this application, and converted into the axial movement of the clamping element 631 along the pipe fitting through the transmission system.
[0024] The overall process of pipe fitting alignment adjustment in this application is roughly as follows: First, the alignment fixture 60 is inserted into the pipe fitting to be connected. The tensioning mechanism 62 is aligned with the connection point of the two pipe fittings. The tensioning mechanism 62 is used for pre-tensioning. Each tensioning block and the pipe fitting just makes contact, but there is no force. Then, the connection gap is adjusted by the gap adjustment mechanism. The tensioning mechanism 62 is used for secondary tensioning. Each tensioning block and the pipe fitting are under force, thus achieving pipe fitting alignment.
[0025] This application is mainly used to adjust and control the alignment status of pipe fittings in the secondary tightening stage by using a closed-loop system consisting of a centering and tightening actuator 30, a centering parameter detection device 40, and a system controller to perform detection, feedback, and execution. Of course, the cooperation between the centering and tightening actuator 30 and the system controller in this application can also achieve pre-tightening and adjustment of the docking gap during the adjustment of the docking gap.
[0026] It should be noted that the meaning of the centering fixture 60 in this application including at least one tensioning mechanism 62 is that, in the centering fixture 60, one tensioning mechanism 62 corresponds to one weld seam. The centering fixture 60 of this application can be used to align the weld seams of two pipe fittings (one weld seam). At this time, the transmission rod 624 of the tensioning mechanism 62 is rotated by external force, thereby driving each tensioning block to move radially to achieve tension until the centering is completed. After the centering is completed, the weld seam is then welded. Alternatively, more pipe fittings (at least two weld seams) can be aligned sequentially, and all weld seams can be aligned before being welded together. Specifically, the weld seams of two pipe fittings are aligned first. After the weld seams are aligned, another pipe fitting (with a central shaft 61 and tensioning mechanism 62 initially installed inside) is connected to the two pipe fittings that have already been aligned. This process of sequentially aligning weld seams is repeated. Figure 4 and Figure 5 The centering fixture 60 is shown to include three tensioning mechanisms 62, which are used to sequentially center the three weld seams of the four pipe fittings.
[0027] Please see Figure 1 and Figure 7 as well as Figure 8 , Figure 7 yes Figure 1 A three-dimensional structural diagram of one of the centering and tightening actuators 30 and the rotary drive mechanism 50 in the pipe fitting weld alignment and adjustment system. Figure 8 yes Figure 1 A three-dimensional structural diagram of another centering and tightening actuator 30 in the pipe fitting weld alignment and adjustment system is shown. The centering and tightening actuator 30 is mounted on the mounting base 10 and includes at least one tightening output end 301. The tightening output end 301 is configured to perform a tightening operation on the tightening input end 601 of the centering fixture 60 to apply a tightening force. The tightening input end 601 of the centering fixture 60 can be the end of the transmission rod 624 of the centering fixture 60. By performing a tightening operation on the end of the transmission rod 624 of the centering fixture 60 through the tightening output end 301 of the centering and tightening actuator 30, the various tensioning blocks of the centering fixture 60 can be driven to extend radially. On the one hand, during the pre-tightening process, the tensioning blocks can be driven to contact the inner wall of the pipe fitting. On the other hand, during the secondary tightening adjustment stage after the butt joint gap adjustment is completed, a tightening force can be applied to the inner wall of the pipe fitting, so that the alignment state of the pipe fitting gradually reaches the qualified standard.
[0028] The alignment parameter detection device 40 is configured to detect the alignment geometric parameters at the pipe fitting joint on the alignment tooling 60 in real time when the alignment tooling 60 rotates to drive the pipe fitting to rotate synchronously. The rotation of the alignment tooling 60 can be driven by external forces such as a motor.
[0029] Among them, the alignment geometric parameters include at least the misalignment amount, which refers to the radial position deviation caused by misalignment when two pipe fittings are joined together, that is, the offset distance of one pipe fitting relative to another pipe fitting in the direction perpendicular to the axis. In this application, the misalignment amount is detected by the alignment parameter detection device 40, specifically using the outer surface as the measurement reference and the height difference of the outer surface as the measurement object. Therefore, the misalignment amount mentioned in this application is based on the reference axis of the inner wall of the pipe fitting established by the alignment tooling 60, and is the radial height difference between the outer surface of the first pipe fitting end and the outer surface of the second pipe fitting end in the direction perpendicular to the axis at the pipe fitting joint.
[0030] The system controller of this application is communicatively connected to the centering and tightening actuator 30 and the centering parameter detection device 40. The system controller is configured as follows: Receive real-time alignment geometric parameters from alignment parameter detection device 40; Based on real-time alignment geometric parameters, determine whether the current alignment status meets the qualification standard; If the qualified standard is not met, the centering and tightening actuator 30 will continue to perform tightening operation on the tightening input end of the centering fixture 60 based on the analysis results of the real-time centering geometric parameters. After further tightening, the alignment geometry parameters are reacquired and re-evaluated until the preset termination conditions are met; the termination conditions include at least one of the following: the alignment status is qualified or the tightening force applied by the alignment tightening actuator 30 reaches a safety threshold.
[0031] The preset termination conditions are set to two. The reason is that for products with qualified processing quality and when the centering tool 60 is installed in place, the qualified centering state will eventually be achieved after repeated testing and tightening by the centering parameter detection device 40 and the centering tightening actuator 30. However, for products with unqualified processing quality (such as two pipe fittings with large differences in diameter) and when the centering tool 60 is not installed in place, the qualified centering state will not be achieved even after repeated testing and tightening by the centering parameter detection device 40 and the centering tightening actuator 30. Furthermore, excessive tightening force may cause the pipe fittings to deform and become unrecoverable, resulting in scrap, or damage to the service life of the centering tool 60.
[0032] For example, the safety threshold for tightening force can be set based on the upper limit of the pipe fitting's deformation torque. Tests have shown that when the inner diameters of the two pipe fittings are between 259mm and 260mm, the upper limit of the pipe fitting's deformation torque is approximately 240 N / m. When the pipe fitting's deformation torque exceeds 240 N / m, the pipe fitting has already failed, and after loosening the tensioning block of the centering fixture 60, the pipe fitting cannot spring back. When the pipe fitting's deformation torque is within 240 N / m, loosening the tensioning block allows the pipe fitting to return to its original size.
[0033] During the alignment adjustment phase (i.e., the secondary tightening phase mentioned above), preliminary tightening is performed first. The alignment parameter detection device 40 detects the alignment geometric parameters. If they are not qualified, the alignment tightening actuator 30 continues to tighten (for example, increasing by 5 N / m each time) until the preset termination condition is met. The system controller can record the torque magnitude of each tightening output end 301 in real time, which facilitates subsequent optimization of the equipment processing technology.
[0034] If the tightening force applied by the centering tightening actuator 30 reaches the safety threshold (the pipe fitting reaches the upper limit of deformation), but the centering state still does not meet the qualified standard, the centering tightening actuator 30 will loosen each tensioning block of the centering fixture 60 and then tighten it again before re-measuring, or the centering fixture 60 will be removed and reinstalled before re-centering, or the pipe fitting will be replaced before re-centering.
[0035] The above-mentioned solution provided in this application establishes a fully closed-loop intelligent adjustment architecture with the alignment geometric parameters as the controlled object, the alignment tightening actuator 30 as the actuator, and the system controller as the decision-making core. Traditional alignment methods rely on manual experience to tighten and observe simultaneously (manual measurement using tools such as dial indicators), resulting in low production efficiency, slow inspection speed, and small inspection range, which affects the welding quality of the product. This application, through the automatic coordination of the alignment parameter detection device 40 and the pipe rotation process, can complete high-precision data acquisition of the entire 360° circumference in a short time without human intervention. It upgrades subjective, vague, and discrete human perception to objective, accurate, and reproducible machine vision measurement. Furthermore, through the qualified judgment algorithm and closed-loop control logic built into the system controller, it automatically compares the inspection data with preset standards, transforming implicit and vague personal experience into explicit, deterministic, and batch-reproducible algorithmic decisions.
[0036] In short, this application encapsulates the entire "detection-judgment-execution-re-inspection" process into an automatic iterative loop through a system controller. Once started, the system runs autonomously until alignment is successful or a safety threshold is triggered, requiring no manual intervention. This mechanism replaces manual labor, avoiding the problem of excessive torque damaging tooling or fittings during manual tightening, and ensuring more accurate detection of alignment geometric parameters. The equipment operates automatically, eliminating the need for direct contact between workers and the workpiece, thus improving the processing quality and pass rate of materials (fittings); reducing production costs; lowering the experience requirements for installation workers; and increasing production efficiency.
[0037] It should be noted that the alignment geometry parameter in this application is typically the misalignment amount. During the pre-tensioning and gap adjustment stage, the adjusted butt joint gap value generally meets the standard. However, during the secondary tensioning stage after gap adjustment, the misalignment amount is often difficult to control within the acceptable range in one go due to deviations in the processing quality of the incoming material, improper installation of the alignment tooling 60, or other external factors. Therefore, multiple checks of the misalignment amount and multiple tightening operations are required to achieve the acceptable standard. Of course, in other embodiments, the butt joint gap value may also be used as the alignment geometry parameter.
[0038] Please continue reading. Figure 1 In some embodiments, the pipe fitting weld alignment adjustment system may further include a rotary drive mechanism 50 for driving the centering fixture 60, which carries the pipe fitting to be aligned, to rotate. Specifically, it drives the central shaft 61 of the centering fixture 60 to rotate around itself, thereby causing the pipe fitting to rotate synchronously. Please refer to [link to relevant documentation]. Figure 9 , Figure 9 yes Figure 1 This is a three-dimensional structural diagram of the rotary drive mechanism 50 in the pipe fitting weld alignment adjustment system. The rotary drive mechanism 50 includes a rotary drive motor 51 and a rotary drive shaft 52. The rotary drive motor 51 is fixed to the translation base 321, and the rotary drive shaft 52 is fixed to the output shaft of the rotary drive motor 51. The rotary drive shaft 52 is parallel to the axial direction of the pipe fitting and is used to fix to the central shaft 61 of the alignment fixture 60 to drive the central shaft 61 to rotate around itself, thereby driving the pipe fitting to rotate synchronously. Since the alignment fixture 60 has already formed a rigid whole with the pipe fitting before the alignment fixture 60 rotates, the rotation of the central shaft 61 of the alignment fixture can synchronously drive the pipe fitting to rotate, improving the automation of the system inspection.
[0039] In this embodiment, the rotary drive motor 51 can also be connected to the system controller. The system controller controls the operation of the rotary drive motor 51. After the initial tightening operation, the system controller controls the rotary drive motor 51 to drive the rotary drive shaft 52 to rotate, and at the same time controls the alignment parameter detection device 40 to detect the alignment geometric parameters. When it is necessary to tighten again, the system controller controls the rotary drive motor 51 to drive the rotary drive shaft 52 to rotate again, and at the same time controls the alignment parameter detection device 40 to detect the alignment geometric parameters again.
[0040] Please refer to the following: Figure 1 and Figure 10 , Figure 10 yes Figure 1A three-dimensional structural diagram of the alignment parameter detection device 40 in the pipe fitting weld alignment adjustment system is shown. In some embodiments, the alignment parameter detection device 40 may include a detection linear drive module 41, a camera bracket 42, and a line scan camera 43. The detection linear drive module 41 is mounted on the mounting base 10. The camera bracket 42 is fixedly connected to the slider of the detection linear drive module 41 and is driven by the detection linear drive module 41 to move in a direction parallel to the pipe fitting axis. The line scan camera 43 is fixedly mounted on the camera bracket 42, and its scanning direction is aligned with the pipe fitting mating point on the alignment fixture 60. The system controller is communicatively connected to the detection linear drive module 41 and the line scan camera 43 and is configured to perform the following detection steps: Control the linear drive module 41 to move the line scan camera 43 to the scanning station at the pipe fitting docking point on the alignment and centering fixture 60; When the centering fixture 60 drives the pipe to rotate, the line scan camera 43 is triggered to continuously scan the joint to obtain the centering parameters of the pipe joint.
[0041] In this embodiment, the detection linear drive module 41 can be a lead screw and slider mechanism. The lead screw and slider mechanism uses a servo motor as a power source. The camera bracket 42 is fixedly connected to the slider of the detection linear drive module 41. The servo motor drives the slider to move, thereby driving the camera bracket 42 and the line scanning camera 43 fixed on it to move in a direction parallel to the axis of the pipe, so that the camera can be moved from a safe position to a scanning position and scanned at the pipe joint.
[0042] The line scan camera 43, as the execution module for centering geometric parameter detection, is driven by the detection linear drive module 41 to move along the axis of the pipe fitting. This allows the line scan camera 43 to be aligned with the pipe fitting joint for detection, enabling it to automatically align with the weld seam position of pipe fittings of different specifications. It is adaptable to pipe fitting products with different pipe lengths and weld seam positions. Furthermore, the rotation of the pipe fitting driven by the centering fixture 60 and the scanning action triggered by the line scan camera 43 are automatically synchronized through the system controller, requiring no manual intervention. The line scan camera 43 continuously acquires data during the uniform rotation of the pipe fitting, obtaining continuous 360° contour data, which improves measurement accuracy.
[0043] In some embodiments, the pipe fitting weld alignment adjustment system further includes a torque monitoring unit (not shown) for real-time monitoring of the adjustment torque output by the alignment tightening actuator 30, and the system controller is also configured to limit the output torque within a preset safety threshold based on feedback from the torque monitoring unit.
[0044] In this embodiment, by setting a torque monitoring unit, the torque applied by the centering and tightening actuator 30 can be monitored in real time. Combined with the system controller, it is easy to determine whether the torque applied by the centering and tightening actuator 30 is within the safety threshold, thus eliminating the risk of overload of the centering tooling 60 and the pipe fitting.
[0045] Specifically, in some embodiments, the centering and tightening actuator 30 includes a tightening drive motor 3221, which may be a servo motor. The tightening drive motor 3221 is used to drive the rotation of the tightening output end 301. The torque monitoring unit is a torque estimation module integrated into the driver of the tightening drive motor 3221, which calculates the output torque by detecting the motor torque current. In this embodiment, the adjustment torque output by the centering and tightening actuator 30 is detected by the torque value automatically fed back by the tightening drive motor 3221, without the need for an additional detection mechanism. Since no additional hardware is required, the system cost is low.
[0046] In other embodiments, the torque monitoring unit is a torque sensor located between the output shaft of the torque drive motor 3221 and the torque output end of the centering torque actuator 30. In this embodiment, by setting an additional torque sensor to detect the adjustment torque output by the centering torque actuator 30, the load torque can be accurately reflected, with high measurement accuracy and small absolute error.
[0047] In some embodiments, there is at least one centering and tightening actuator 30. When there is one centering and tightening actuator 30, the centering and tightening actuator 30 can tighten from one side of the pipe to be centered. When there are two centering and tightening actuators 30, the two ends of the tightening transmission rod of the centering tool 60 extend from the two ends of the pipe to be centered, and the two ends of the tightening transmission rod respectively form a tightening input end. The centering and tightening actuator 30 can tighten from both sides of the pipe to be centered at the same time.
[0048] like Figure 1 As shown, in some embodiments, there are two centering and tightening actuators 30, including a first centering and tightening actuator 30A and a second centering and tightening actuator 30B. The first centering and tightening actuator 30A and the second centering and tightening actuator 30B are respectively located on opposite sides of the centering fixture 60 along the axial direction of the pipe fitting. Figure 7 and Figure 8 As shown, Figure 7 yes Figure 1 A three-dimensional structural diagram of the first centering tightening actuator 30A in the pipe fitting weld alignment adjustment system. Figure 8 yes Figure 1 A three-dimensional structural diagram of the second centering tightening actuator 30B in the pipe fitting weld alignment adjustment system. This embodiment improves tightening efficiency through tightening from both sides.
[0049] Continue reading Figure 7 and Figure 8 The centering and tightening actuator 30 includes a tightening linear drive module 31 and a tightening mechanism 32. The tightening linear drive module 31 is mounted on the mounting base 10. The tightening mechanism 32 is fixedly connected to the slider of the tightening linear drive module 31 and is driven by the tightening linear drive module 31 to move in a direction parallel to the axis of the pipe. The tightening output end 301 is located on the tightening mechanism 32.
[0050] In this embodiment, the tightening mechanism 32 serves as the actuator of the centering tightening execution mechanism 30. The tightening mechanism 32 can be driven by the tightening linear drive module 31 to move in a direction parallel to the axis of the pipe fitting, which facilitates the movement of the tightening mechanism 32 between the initial position and the tightening position. This facilitates the tightening mechanism 32 to disengage from and be fixed to the tightening input end 601 of the centering fixture 60, and to avoid the centering fixture 60 when the fixture carrying device 20 drives the centering fixture 60 carrying the pipe fitting to move between the working position and the loading and unloading position.
[0051] The tightening linear drive module 31 can adopt a lead screw and slider mechanism. The lead screw and slider mechanism uses a servo motor as a power source. The tightening mechanism 32 is connected to the slider of the tightening linear drive module 31. The servo motor drives the slider to move, thereby driving the tightening mechanism 32 to move in a direction parallel to the axis of the pipe, so that the tightening mechanism 32 can move between the initial position and the tightened position.
[0052] In one specific embodiment, the tightening mechanism 32 includes a translation base 321 and a plurality of tightening elements 322; the translation base 321 is fixedly connected to the slider of the tightening linear drive module 31; each tightening element 322 includes a tightening drive motor 3221 and a tightening shaft 3222, the tightening drive motor 3221 is fixed to the translation base 321, the tightening shaft 3222 is fixed to the output shaft of the tightening drive motor 3221, the tightening shaft 3222 is parallel to the axial direction of the pipe, and the tightening shaft 3222 is at least used to fix to the tightening input end 601 of the centering fixture 60 to drive the tightening input end 601 to rotate around its own axis, thereby realizing the radial tightening of the tensioning block of the centering fixture 60.
[0053] In this embodiment, the translation base 321 serves as the mounting and bearing mechanism for multiple tightening components 322. The number of tightening components 322 is the same as the number of tightening input ends 601 in the centering fixture 60. One tightening component 322 corresponds to one tightening input end 601. The tightening component 322 uses a tightening drive motor 3221 as a power source to drive the tightening shaft 3222 to rotate. The end of one tightening shaft 3222 constitutes a tightening output end 301. To fix the tightening shaft 3222 to the tightening input end 601 in the centering fixture 60 to drive the tightening input end to rotate, the tightening output end 301 in this embodiment can be a tuning fork type clamping head. This tuning fork type clamping head includes two opposing clamping arms, with a profile-fitting cavity formed between the two clamping arms that matches the end profile of the transmission rod 624 of the centering fixture 60. The end of the transmission rod 624 has a non-circular cross-sectional profile. When the tightening member 322 moves along a direction parallel to the axis of the pipe via the translation base 321, the outer periphery of the end of the transmission rod 624 inserts into the profile-fitting cavity of the tuning fork type clamping head, and the non-circular cross-sectional profile of the end of the transmission rod 624 forms a circumferential limiting fit with the profile-fitting cavity of the tuning fork type clamping head to transmit rotational torque. In this embodiment, the tightening output end 301 and the tightening input end 601 can be docked, fixed, and separated by the linear movement of the tightening member 322 along a direction parallel to the axis of the pipe. The structure is simple, reliable, and easy to operate.
[0054] When there are two centering and tightening actuators 30, the rotary drive mechanism 50 is disposed in one of the first centering and tightening actuator 30A and the second centering and tightening actuator 30B, for example, as follows: Figure 7 As shown, the rotary drive mechanism 50 is disposed between the first centering torque actuator 30A and between the multiple torque members 322 and spaced apart from the multiple torque members 322, so as to make reasonable use of the equipment space.
[0055] This application also provides a closed-loop system for aligning and adjusting pipe fitting welds, including an alignment fixture carrying the pipe fitting to be aligned and a pipe fitting weld alignment and adjustment system. For details on the structure and principle of the alignment fixture 60 and the pipe fitting weld alignment and adjustment system, please refer to the above embodiments, which will not be repeated in this embodiment.
[0056] This application also provides a method for aligning and adjusting pipe fitting welds, which is performed using the pipe fitting weld alignment and adjustment system described in the above embodiments. Please refer to [link to relevant documentation]. Figure 11 , Figure 11 This is a flowchart of a pipe fitting weld alignment and adjustment method provided in an embodiment of this application. The method includes the following steps: S11. The torque output end of the centering and tightening actuator performs a torque operation on the torque input end of the centering fixture that carries the pipe fitting to be centered in order to apply torque force. S12. The torque output end of the centering and tightening actuator is disengaged from the torque input end of the centering fixture, and the centering fixture carrying the pipe fitting to be centered performs a rotational action. S13: During the rotation process, the alignment geometric parameters at the pipe fitting joint on the alignment tooling are detected in real time; S14: Based on the real-time detected centering geometric parameters, determine whether the current centering state meets the qualification standard; S15: If it is determined that the qualified standard has not been met, then according to the analysis results of the real-time alignment geometric parameters, the tightening input end of the alignment tooling shall continue to perform tightening operation on the tightening input end of the alignment tooling. S16: After performing the continued tightening operation, the centering geometric parameters are reacquired and re-judged until the preset termination condition is met. The termination condition includes at least one of the following: the centering state is qualified or the tightening force applied by the centering tightening actuator reaches a safety threshold.
[0057] The pipe fitting weld alignment adjustment method provided in this application encapsulates the entire process of "inspection-judgment-execution-re-inspection" into an automatic iterative cycle. After one start, the system runs autonomously until the alignment is qualified or the safety threshold is triggered, without the need for manual intervention throughout the process, thus improving the alignment quality and efficiency of pipe fittings.
[0058] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0059] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.
Claims
1. A pipe weld alignment adjustment system, characterized by, Comprising: a mounting base; a tool carrying device arranged on the mounting base for carrying and fixing a centering tool to which a pipe to be centered is clamped; a centering and tightening execution mechanism arranged on the mounting base, comprising at least one tightening output end configured to perform a tightening operation on a tightening input end of the centering tool to apply a tightening force; a centering parameter detection device configured to detect in real time a centering geometric parameter at a pipe joint of the centering tool when the centering tool rotates to drive the pipe to rotate synchronously; and a system controller in communication connection with the centering and tightening execution mechanism and the centering parameter detection device, the system controller being configured to: receive the real-time centering geometric parameter from the centering parameter detection device; judge whether the current centering state reaches a qualified standard based on the real-time centering geometric parameter; if the qualified standard is not reached, control the centering and tightening execution mechanism to continue performing the tightening operation on the tightening input end of the centering tool according to the analysis result of the real-time centering geometric parameter; after the tightening continues, the centering geometric parameter is re-acquired and the judgment is re-performed until a preset termination condition is met; the termination condition includes at least one of a qualified centering state or a tightening force applied by the centering and tightening execution mechanism reaching a safety threshold.
2. The pipe weld alignment adjustment system according to claim 1, wherein the centering geometric parameter at least includes a misalignment amount.
3. The pipe weld alignment adjustment system according to claim 1, wherein the system further comprises a torque monitoring unit for monitoring in real time an adjustment torque output by the centering and tightening execution mechanism, and the system controller is further configured to limit the output torque within a preset safety threshold according to the feedback of the torque monitoring unit. In the centering and tightening execution mechanism, a tightening drive motor is used to drive the rotation of the tightening output end, and the torque monitoring unit is a torque estimation module integrated in a driver of the tightening drive motor to calculate the output torque by detecting the motor torque current. Alternatively, the torque monitoring unit is a torque sensor arranged between an output shaft of the tightening drive motor and the torque output end of the centering and tightening execution mechanism.
4. The pipe weld alignment adjustment system according to claim 1, wherein the centering and tightening execution mechanism is at least one, and the centering and tightening execution mechanism comprises: a tightening linear drive module mounted on the mounting base; a tightening mechanism fixedly connected with a slider of the tightening linear drive module and driven by the tightening linear drive module to move in a direction parallel to the pipe axis, and the tightening output end is arranged on the tightening mechanism.
5. The pipe weld alignment adjustment system according to claim 4, wherein the tightening mechanism comprises: a translation base fixedly connected with the slider of the tightening linear drive module. A plurality of tightening members, each of the tightening members comprising a tightening drive motor and a tightening shaft, the tightening drive motor being fixed to the translation base, the tightening shaft being fixed to an output shaft of the tightening drive motor, the tightening shaft being parallel to the axial direction of the pipe, the tightening shaft being used to fix to the tightening input end of the centering tool to drive the tightening input end to rotate around its own axis, so as to realize the radial tightening of the tightening block of the centering tool.
6. The pipe weld alignment adjustment system according to claim 5, wherein, the centering and tightening execution mechanism is two, the two centering and tightening execution mechanisms comprising a first centering and tightening execution mechanism and a second centering and tightening execution mechanism, the first centering and tightening execution mechanism and the second centering and tightening execution mechanism being located on opposite sides of the centering tool along the axial direction of the pipe; the centering tool comprises a tightening transmission rod, both ends of the tightening transmission rod respectively constituting a tightening input end; the first centering and tightening execution mechanism and the second centering and tightening execution mechanism are respectively used to perform a tightening action on the tightening input end of both ends of the tightening transmission rod.
7. The pipe weld alignment adjustment system according to claim 6, wherein, the system further comprises a rotation drive mechanism for driving the centering tool carrying the pipe to be centered to rotate; wherein the rotation drive mechanism is arranged on one of the first centering and tightening execution mechanism and the second centering and tightening execution mechanism, and is arranged between and spaced apart from the plurality of tightening members, the rotation drive mechanism comprising a rotation drive motor and a rotation drive shaft, the rotation drive motor being fixed to the translation base, the rotation drive shaft being fixed to an output shaft of the rotation drive motor, the rotation drive shaft being parallel to the axial direction of the pipe, the rotation drive shaft being used to fix to the central shaft of the centering tool to drive the central shaft to rotate around itself to drive the pipe to rotate synchronously.
8. The pipe weld alignment adjustment system according to claim 1, wherein, the centering parameter detection device comprises: a detection linear drive module mounted on the mounting base; a camera support fixedly connected with the sliding block of the detection linear drive module and driven by the detection linear drive module to move in a direction parallel to the axial direction of the pipe; a line-scan camera fixedly mounted on the camera support, the scanning direction of the line-scan camera being aligned with the pipe joint on the centering tool; wherein the system controller is in communication connection with the detection linear drive module and the line-scan camera, and is configured to perform the following detection steps: controlling the detection linear drive module to move the line-scan camera to a scanning station aligned with the pipe joint on the centering tool; triggering the line-scan camera to continuously scan the joint to obtain the centering parameters of the pipe joint when the centering tool drives the pipe to rotate.
9. A pipe weld alignment adjustment closed-loop system, comprising a centering tool carrying a pipe to be centered and a pipe weld alignment adjustment system according to any one of claims 1 to 8.
10. A method of pipe joint weld alignment adjustment, characterized by, The method is performed by using the system as claimed in any one of claims 1 to 8, and comprises the following steps: a torque output end of a centering and torqueing execution mechanism performs a torqueing operation on a torqueing input end of a centering tool carrying a pipe to be centered to apply a torqueing force; the torque output end of the centering and torqueing execution mechanism is disengaged from the torqueing input end of the centering tool, and a rotating action is performed on the centering tool carrying the pipe to be centered; in the rotating process, a centering geometric parameter at a pipe butt joint of the centering tool is detected in real time; based on the real-time detected centering geometric parameter, it is determined whether a current centering state reaches a qualified standard; if it is determined that the qualified standard is not reached, the torqueing input end of the centering tool continues to perform a torqueing operation on the torqueing input end of the centering tool according to an analysis result of the real-time centering geometric parameter; after the torqueing operation is performed, the centering geometric parameter is re-acquired and the determination is re-performed until a preset termination condition is met, the termination condition including at least one of a qualified centering state or a torqueing force applied by the centering and torqueing execution mechanism reaching a safety threshold.