Submerged-arc welding equipment and welding process for hot-wall hydrogenation reactor

Abstract

The invention relates to the technical field of submerged-arc welding, in particular to submerged-arc welding equipment for a hot-wall hydrogenation reactor and a welding technology.The submerged-arc welding equipment for the hot-wall hydrogenation reactor comprises a blocking frame, a machine base, a first stock bin, a welding head and two first partition plates, the first stock bin, the welding head and the two first partition plates are arranged on the machine base, and the blocking frame is located on the inner side of a shell and used for blocking a longitudinal seam from the inner side; the machine base is located on the outer side of the shell and can slide in the direction parallel to the longitudinal seam. The first stock bin is used for conveying the welding flux into the longitudinal seam; the welding head is located on the rear side of the first stock bin in the welding direction and used for welding the longitudinal seam through a welding wire and a welding flux. The two first partition plates are both arranged on the machine base and located on the two sides of the longitudinal seam respectively, a first storage space with the large size from inside to outside is formed between the two first partition plates, and under the limitation of the first storage space, welding flux forms a stacking shape with the large size from inside to outside, and the whole welding flux forms a relatively loose structure, so that the laying thickness can be guaranteed, and the welding flux can be laid more stably. And the air permeability can be ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of submerged arc welding, in particular to a hot-wall hydrogen reactor submerged arc welding device and welding process. BACKGROUND

[0002] The hot-wall hydrogen reactor is a key equipment in the core field of petroleum refining, chemical industry, etc., and its running stability and safety directly determine the efficiency and reliability of the entire hydrogenation process. The structural integrity of the hot-wall hydrogen reactor shell is the basis for long-term stable operation of the equipment, and the longitudinal seam welding quality is the core influencing factor of the shell structure strength. In the processing link of the longitudinal seam of the hot-wall hydrogen reactor shell, submerged arc welding becomes the mainstream welding method due to its characteristics of adapting to large thick-walled component welding.

[0003] The core working principle of submerged arc welding is to use the high temperature generated by the electric arc burning under the flux layer to melt the welding wire and the base metal to form a molten pool. At the same time, the flux is partially melted under the action of high temperature to form a slag, which protects the molten pool, deoxidizes and improves the weld formation. The coverage of the flux layer not only effectively isolates the electric arc from the outside air, avoiding the reaction of oxygen, nitrogen and other gases in the air with the high-temperature molten pool, reducing the generation of pores, slag and other defects in the weld, and ensuring the stability of the welding quality; but also greatly reduces the arc radiation and noise pollution in the welding process through the heat and sound insulation effect of the flux layer, and concentrates the arc heat to speed up the melting speed of the welding wire.

[0004] However, in the actual welding operation of the longitudinal seam of the hot-wall hydrogen reactor shell, a relatively thick flux layer is usually laid in the longitudinal seam area. Although this can further strengthen the protection effect of the flux on the molten pool, it will also significantly reduce the overall permeability of the flux, making it difficult for the gas generated by the flux to escape, causing the gas to accumulate on the surface of the molten pool and push away the molten pool liquid, and then causing the molten pool liquid to leave a depression or hole after solidification, thereby damaging the stability and strength of the weld. SUMMARY

[0005] Therefore, it is necessary to provide a hot-wall hydrogen reactor submerged arc welding device and welding process to solve the problems of poor stability and low strength after the longitudinal seam welding of the hot-wall hydrogen reactor shell is completed.

[0006] The above-mentioned purpose is achieved by the following technical solutions: A hot-wall hydrogen reactor submerged arc welding device, the hot-wall hydrogen reactor submerged arc welding device comprising: A plug frame located on the inside of the shell and configured to plug the longitudinal seam from the inside; A machine base located on the outside of the shell and capable of sliding in a direction parallel to the longitudinal seam; The first material bin is arranged on the base and is configured to store the welding flux; a first discharge opening is formed in the first material bin and is in communication with the longitudinal seam, and the welding flux can enter the longitudinal seam through the first discharge opening; The welding head is arranged on the base and is located at the rear side of the first material bin along the welding direction; a welding wire is inserted into the welding head; the welding head is configured to weld the longitudinal seam by the welding wire and the welding flux; The two first partitions are arranged on the base and are located at the two sides of the longitudinal seam respectively, and a first storage space is formed between the two first partitions from the inside to the outside, the first storage space is located between the first discharge opening and the longitudinal seam, and is in communication with the first discharge opening and the longitudinal seam at the same time.

[0007] Further, the first partition is in a strip structure, extends along a direction parallel to the longitudinal seam, and has a V-shaped cross-sectional shape, and the V-shaped tips of the two first partitions are oppositely arranged.

[0008] Further, the base is further provided with a second material bin, the second material bin is located at the front side of the first material bin along the welding direction, and is configured to store the remaining welding flux on the shell; a second discharge opening is formed in the second material bin and is in communication with the longitudinal seam, and the remaining welding flux on the shell can enter the longitudinal seam through the second discharge opening; the hot-wall hydrogenation reactor submerged arc welding equipment further comprises a collecting assembly, and the collecting assembly is configured to collect the remaining welding flux on the shell into the second material bin.

[0009] Further, the collecting assembly comprises a suction member, a suction end of the suction member is in communication with the remaining welding flux on the shell, and a discharge end is in communication with the second material bin.

[0010] Further, the collecting assembly further comprises a brush, the brush is arranged on the base and is located at the rear side of the welding head along the welding direction, and can reciprocate along the circumferential direction of the shell, and the brush is configured to move the remaining welding flux on the shell in the circumferential direction; the base is further provided with two classification plates, two first collecting bins and two second collecting bins, the two classification plates are located at the two sides of the longitudinal seam respectively, and are configured to classify the remaining welding flux on the shell according to different sizes; the two first collecting bins are located at the two sides of the longitudinal seam respectively, and are configured to collect the remaining welding flux on the shell smaller than a preset size; the two second collecting bins are located at the two sides of the longitudinal seam respectively, and are configured to collect the remaining welding flux on the shell larger than the preset size; the number of the suction members is two, and the suction ends of the two suction members are in communication with the two first collecting bins respectively.

[0011] Further, the brush is provided with two connecting rods, and the two classification plates are rotatably sleeved on the two connecting rods respectively; the base is provided with two racks, and the two racks are located at the two sides of the longitudinal seam respectively; a synchronous gear is fixedly arranged on each classification plate, the synchronous gear is rotatably sleeved on the connecting rod, and is engaged with the rack.

[0012] Furthermore, the machine base is also provided with two second partitions, which are located on both sides of the longitudinal seam and within the first storage space, forming a second storage space between them. The second storage space is located between the second discharge port and the longitudinal seam, and is simultaneously connected to the second discharge port and the longitudinal seam.

[0013] Furthermore, a bucket is also provided on the base, which is located behind the welding head along the welding direction and is configured to remove welding slag from the casing.

[0014] Furthermore, the base is also equipped with two third collection chambers, which are located on both sides of the longitudinal seam and are configured to collect welding slag on the shell.

[0015] The present invention also provides a submerged arc welding process for a hot-wall hydrogenation reactor, which employs a submerged arc welding device for a hot-wall hydrogenation reactor. The submerged arc welding process for a hot-wall hydrogenation reactor includes the following steps: S1. Place the plug inside the housing and seal the longitudinal seam from the inside using the plug; S2. Place the flux into the first hopper; S3. Drive the machine base to slide in a direction parallel to the longitudinal seam. The flux enters the longitudinal seam through the first discharge port and forms a stacked shape from the inside to the outside under the limitation of the two first partitions. S4. The welding head is used to weld the longitudinal seam using welding wire and flux.

[0016] The beneficial effects of this invention are: This invention relates to a submerged arc welding device and welding process for a hot-wall hydrogenation reactor. By setting two first baffles, the flux is stacked in a large-to-small shape from the inside out, while the flux as a whole forms a relatively loose structure. This ensures both the thickness of the flux layer and the permeability, facilitating the release of gases generated by the flux and improving the stability and strength of the weld.

[0017] Furthermore, by setting up a second hopper and a collection component, the remaining flux on the shell can be collected into the second hopper under the action of the collection component. This not only makes full use of the flux but also reduces the trouble of subsequent collection steps. Moreover, by utilizing the positional characteristics of the second hopper, it is ensured that the remaining flux on the shell in the second hopper can reach the longitudinal seam before the flux in the first hopper. Since the remaining flux on the shell has residual heat, there is no need to set up an additional heating device to heat the flux in the longitudinal seam. This not only achieves heat recycling but also reduces costs and energy consumption.

[0018] Furthermore, by setting up a brush and a corresponding sorting plate, a first collection bin, and a second collection bin, the brush facilitates the movement of the remaining flux on the shell to the sorting plate. Then, by utilizing the sorting characteristics of the sorting plate, the remaining flux on the shell is sorted according to different sizes and collected through the first and second collection bins respectively. This ensures that the remaining flux on the shell collected in the second bin is of appropriate size, thereby guaranteeing the subsequent welding quality.

[0019] Furthermore, by setting up connecting rods, synchronous gears, and racks, and utilizing the rotational characteristics of the sorting plate, the connecting rods synchronously drive the sorting plate to follow the brush movement during the brushing process. At the same time, under the meshing action of the synchronous gears and racks, the sorting plate is synchronously driven to rotate. Thus, through the compound motion of the sorting plate, it generates vibration, preventing the sorting plate from clogging and ensuring the sorting effect of the sorting plate.

[0020] Furthermore, by setting two second partitions and utilizing the structural characteristics of the second partitions, it is ensured that the remaining flux on the inner shell of the second hopper can be accurately laid directly above the longitudinal seam, thereby utilizing the residual heat of the remaining flux on the shell to increase the melting efficiency of the flux and ensure the quality and efficiency of welding.

[0021] Furthermore, by setting up a bucket, welding slag on the casing can be automatically removed during the movement of the machine base, reducing the hassle of subsequent cleaning steps. Attached Figure Description

[0022] Figure 1 A three-dimensional structural diagram of the submerged arc welding equipment for a hot-wall hydrogenation reactor provided in an embodiment of the present invention during the welding of the longitudinal seam of the shell. Figure 2 An exploded view of the components of the submerged arc welding equipment for the hot-wall hydrogenation reactor provided in an embodiment of the present invention during the welding of the longitudinal seam of the shell. Figure 3 Exploded view of some parts of the submerged arc welding equipment for a hot-wall hydrogenation reactor provided in an embodiment of the present invention. Figure 1 ; Figure 4 Exploded view of some parts of the submerged arc welding equipment for a hot-wall hydrogenation reactor provided in an embodiment of the present invention. Figure 2 ; Figure 5 Exploded view of some parts of the submerged arc welding equipment for a hot-wall hydrogenation reactor provided in an embodiment of the present invention. Figure 3 ; Figure 6 This is a three-dimensional structural diagram of a submerged arc welding device for a hot-wall hydrogenation reactor provided in an embodiment of the present invention. Figure 7 for Figure 6A magnified schematic diagram of the structure at point Y in the middle; Figure 8 This is a side view of the submerged arc welding equipment for a hot-wall hydrogenation reactor provided in an embodiment of the present invention when welding the longitudinal seam of the shell. Figure 9 for Figure 8 Sectional view along the AA direction; Figure 10 for Figure 8 A magnified schematic diagram of the structure at point Z in the middle.

[0023] in: 1. Base; 101. Support bar; 102. Stand; 103. Drive cylinder; 2. Blocking the frame; 3. Base; 301. Second arc plate; 302. Slide groove; 303. Guide plate; 4. First silo; 5. Welding joint; 6. First partition; 7. Second hopper; 801. Brush; 802. Sorting plate; 803. First collection bin; 804. Second collection bin; 805. Conveying pipe; 806. Connecting rod; 807. Rack; 808. Synchronizing gear; 9. Second partition; 10. Bucket; 11. Third collection chamber; 12. Wire feeding assembly; 1201. Welding wire spool; 1202. Wire feed bin; 1203. Drive gear; 1204. Driven wheel; 13. Shell; 1301. Longitudinal seam. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0025] The component designations used in this document, such as "first" and "second," are merely for distinguishing the described objects and do not have any sequential or technical meaning. The terms "connection" and "linkage," unless otherwise specified, include both direct and indirect connections (linkages). In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention.

[0026] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0027] The following reference Figures 1 to 10 The submerged arc welding equipment for hot-wall hydrogenation reactors provided in this embodiment of the invention is particularly suitable for welding the longitudinal seam 1301 of the shell 13 of a hot-wall hydrogenation reactor. Of course, it is also suitable for welding the longitudinal seam 1301 on the cylinder or pipe of other equipment.

[0028] Specifically, the submerged arc welding equipment for the hot-wall hydrogenation reactor is configured to include a base 1, a blocking frame 2, and a base 3. Two support bars 101 are provided on the top of the base 1. The two support bars 101 are arranged horizontally at intervals in the left-right direction and extend horizontally in the front-back direction. The top of the support bars 101 is an arc-shaped surface to facilitate surface contact with the outer peripheral wall of the shell 13. The shell 13 is placed on top of the two support bars 101 during welding and extends horizontally in the front-back direction. A longitudinal seam 1301 is formed on the top of the shell 13 and extends horizontally in the front-back direction.

[0029] The blocking frame 2 is located inside the housing 13 and is used to seal the longitudinal seam 1301 from the inside to prevent flux from falling from the bottom of the longitudinal seam 1301. The base of the blocking frame 2 is a first arc plate, which is located inside the bottom of the housing 13 and forms a surface contact with the inner peripheral wall of the housing 13. A vertical plate is provided on the top of the first arc plate. The vertical plate is set vertically and extends horizontally in the front-back direction. A baffle is provided on the top of the vertical plate. The baffle extends horizontally in the front-back direction and seals the bottom of the longitudinal seam 1301.

[0030] To facilitate the installation of the base 3, a vertical support 102 is provided on the top of the base 1. The vertical support 102 is vertically positioned and located on the rear side of the housing 13. A drive cylinder 103 is provided on the vertical support 102, and the output shaft of the drive cylinder 103 is horizontally facing forward. The base 3 is mounted on the output shaft of the drive cylinder 103 and is located outside the housing 13 and above the longitudinal seam 1301. When the output shaft of the drive cylinder 103 extends or retracts, it can drive the base 3 to slide in a direction parallel to the longitudinal seam 1301.

[0031] It is understandable that the drive cylinder 103 can be configured as any one of a hydraulic cylinder, a pneumatic cylinder, or an electric cylinder.

[0032] The base 3 is equipped with a first hopper 4 for storing flux. A first discharge port is located at the bottom of the first hopper 4, corresponding to and communicating with the longitudinal seam 1301, allowing flux to enter the longitudinal seam 1301 through the first discharge port. The base 3 is also equipped with a welding head 5, located behind the first hopper 4 along the welding direction. Welding wire is inserted into the welding head 5, which is used to weld the longitudinal seam 1301 using the welding wire and flux.

[0033] During use, the housing 13 is first placed on top of the two support bars 101; then flux is added to the first hopper 4; then the drive cylinder 103 is activated, and its output shaft extends, synchronously driving the first hopper 4 and the welding head 5 to move from back to front. During the movement of the first hopper 4, flux falls into the longitudinal seam 1301 through the first outlet under gravity. During the movement of the welding head 5, the welding head 5 welds the longitudinal seam 1301 using welding wire and flux.

[0034] While the above process enables welding of the longitudinal seam 1301 of the hot-wall hydrogenation reactor shell 13, in actual welding operations, a thicker flux layer is typically laid in the weld area to further enhance the protective effect of the flux on the molten pool. A thicker flux layer does indeed more thoroughly isolate the molten pool from external air, reducing air contamination and theoretically improving weld purity. However, a thicker flux layer also significantly reduces the overall permeability of the flux. During welding, the flux undergoes a series of physicochemical changes at high temperatures, such as moisture evaporation and organic matter decomposition, generating a large amount of gas. Simultaneously, the metal elements in the molten pool react with the flux and air (even with only slight penetration) to generate gas.

[0035] Due to the poor permeability of the thick flux layer, the generated gases cannot escape through the flux layer in a timely manner and can only accumulate inside or on the surface of the molten pool. As the welding process progresses, the molten pool gradually cools and solidifies. If the accumulated gases cannot escape smoothly before the molten pool is completely solidified, pressure will form inside the liquid metal. When the gas pressure is sufficient to push away the not-yet-fully-solidified liquid metal, it will leave depressions (if some gas escapes, the remaining space forms a local depression) or pores (if the gas is completely encased in the solidified metal, it forms a closed pore) inside or on the surface of the weld. These depressions and pores will disrupt the continuity and integrity of the weld, leading to stress concentration areas inside the weld. This not only reduces the mechanical properties of the weld (such as tensile strength and impact toughness) but also undermines the stability of the welded structure. During the subsequent operation of the hot-wall hydrogenation reactor, these defects may become the starting point for stress corrosion cracking or fatigue failure, seriously threatening the safe operation of the hot-wall hydrogenation reactor.

[0036] Based on this, in the submerged arc welding equipment for the hot-wall hydrogenation reactor provided in this embodiment of the invention, two first partitions 6 are provided on the base 3. The two first partitions 6 are located on both sides of the longitudinal seam 1301 and are symmetrically arranged about the longitudinal seam 1301. The first partitions 6 are strip-shaped structures and extend in a direction parallel to the longitudinal seam 1301, and at least cover the first material bin 4 and the welding head 5. The cross-sectional shape of the first partitions 6 is V-shaped. The V-shaped tips of the two first partitions 6 are arranged opposite to each other. A first material storage space of a larger size from the inside to the outside is formed between the two first partitions 6. The first material storage space is located between the first discharge port and the longitudinal seam 1301, and is simultaneously connected to the first discharge port and the longitudinal seam 1301.

[0037] As the first hopper 4 moves along the welding direction and delivers flux to the longitudinal seam 1301, the flux first enters the first storage space formed by the two first partitions 6. Since the cross-sections of the two first partitions 6 are V-shaped and their tips face each other, their inner sides form an inwardly inclined support surface. When the flux falls into the first storage space, some of the flux will contact and rest on the inner upper inclined surface of the first partition 6. At this time, the gravity of this part of the flux is no longer completely borne by the flux below or the bottom of the longitudinal seam 1301, but is transferred through the contact surface to the first partition 6, forming a gravity sharing effect.

[0038] Compared to a situation where there is no baffle support and the flux's weight is entirely borne by the lower layer, this weight distribution reduces the flux's density in two ways. First, the lower layer of flux does not need to bear the pressure of all the flux above, resulting in a significant decrease in its own compressive density. Second, tiny gaps are formed between the flux resting on the baffle surface and the flux below, and the inclined structure of the baffle guides the flux to be distributed in a loosely stacked manner, preventing the flux from forming a densely packed layer due to gravity.

[0039] Ultimately, the flux in longitudinal seam 1301 and the first storage space will form a loosely stacked structure. This structure maintains the required thickness for molten pool protection while improving permeability through internal gaps. During welding, gases generated by the flux at high temperatures (such as moisture evaporation and organic decomposition gases) can quickly escape upwards through these loose gaps, preventing accumulation on the molten pool surface. Simultaneously, the smooth escape of these gases reduces their compression of the unsolidified liquid metal, fundamentally lowering the probability of weld defects such as depressions and voids, thereby ensuring the continuity and integrity of the weld and improving the stability and mechanical strength of the welded structure.

[0040] In a further embodiment, during the submerged arc welding of the longitudinal seam 1301 of the hot-wall hydrogenation reactor shell 13, the flux melting efficiency is directly related to the continuity of the welding process and the overall efficiency. Ambient temperature is a key external factor affecting the initial state of the flux. When the ambient temperature is low, the flux maintains a lower initial temperature, resulting in lower kinetic energy of its internal particles and relatively stronger intermolecular forces. During welding, although the electric arc provides a high-temperature heat source, when facing a low-temperature flux, some heat must first be consumed to raise the flux's own temperature to the melting threshold before the melting reaction can occur. This process prolongs the thermal action time of the flux by the electric arc, leading to a reduction in the amount of flux that can be melted per unit time. This, in turn, slows down the formation rate of the molten pool, reduces the efficiency of the weld cladding layer advancement, and ultimately worsens the overall welding efficiency.

[0041] To address the issue of low flux melting efficiency at low temperatures, the conventional approach is to preheat the flux. Current mainstream flux preheating methods often rely on additional heating devices (such as electric furnaces or hot air preheaters), but this method suffers from high costs and energy consumption.

[0042] Based on this, in the submerged arc welding equipment for the hot-wall hydrogenation reactor provided in this embodiment of the invention, a second hopper 7 is further provided on the base 3. The second hopper 7 is located in front of the first hopper 4 along the welding direction and is used to store the remaining flux on the shell 13. A second discharge port is provided at the bottom of the second hopper 7. The second discharge port corresponds to and communicates with the longitudinal seam 1301, and the remaining flux on the shell 13 can enter the longitudinal seam 1301 through the second discharge port. The submerged arc welding equipment for the hot-wall hydrogenation reactor is also provided with a collection component, which includes a suction component. The suction component can be configured as a suction pump. The suction end of the suction pump is connected to the remaining flux on the shell 13 through a pipe, and the discharge end is connected to the second hopper 7 through a pipe, thereby enabling the remaining flux on the shell 13 to be collected into the second hopper 7.

[0043] In this way, under the action of the suction pump, the remaining flux scattered on the surface of the shell 13 can be efficiently sucked into the second hopper 7 for storage. On the one hand, this realizes the recycling of flux and avoids material loss; on the other hand, it eliminates the need for subsequent manual cleaning of residual flux on the shell 13, simplifying the welding process. Furthermore, taking advantage of the position of the second hopper 7 in front of the first hopper 4, when the machine base 3 slides along the longitudinal seam 1301 for welding operations, the second hopper 7 will reach the welding area before the first hopper 4, and the remaining flux stored inside will preferentially be laid to the longitudinal seam 1301 through the second outlet. Crucially, this remaining flux, having just left the high-temperature welding area, still retains some residual heat, maintaining a relatively high initial temperature without relying on additional heating devices. By utilizing the residual heat of the remaining flux, the initial temperature of the flux at longitudinal seam 1301 can be directly increased, reducing the heat consumption and time cost required for the electric arc to heat the flux to a molten state. This avoids the purchase and maintenance costs of additional heating devices, reduces energy consumption, and ensures flux melting efficiency, indirectly maintaining the continuity and stability of welding operations, thus forming a closed-loop optimization of material reuse, heat circulation, and cost reduction.

[0044] In a further embodiment, the curved structure of the housing 13 easily causes the flux to slide along the tangent of the curved surface under its own gravity, forming a scattered state. This scattered flux, on the one hand, will scatter in the welding operation area, damaging the cleanliness of the working environment and potentially interfering with the normal operation trajectory of the welding equipment; on the other hand, the scattered flux needs to be manually cleaned and collected one by one, which not only increases additional manpower input, but also makes manual cleaning difficult to adapt to the complex shape of the curved surface, resulting in cumbersome and time-consuming cleaning operations, significantly reducing the overall efficiency of the welding operation.

[0045] Meanwhile, the flux remaining on the surface of the shell 13 is prone to uneven size due to the high temperature, collision, and compression during the welding process. Larger flux particles may collide with the internal channels and impeller of the suction pump during its return to the second hopper 7, causing wear and even damaging its suction function. After entering the second hopper 7, larger flux particles may also become stuck in the second outlet channel, causing blockage and affecting the stable delivery of flux to the longitudinal seam 1301. Even if it successfully enters the longitudinal seam 1301, larger flux particles are difficult to evenly fill the gaps, easily forming localized accumulations or voids, disrupting the continuity and integrity of the flux layer. This leads to uneven protection of the arc and molten pool, increasing the probability of defects such as slag inclusions and porosity in the weld, ultimately affecting the stability of the welding quality.

[0046] Based on this, in the submerged arc welding equipment for the hot-wall hydrogenation reactor provided in this embodiment of the invention, the base 3 is configured to have two second arc plates 301, which are coaxially arranged with the shell 13. Both second arc plates 301 are slidably arranged on the outer side wall of the shell 13 and are symmetrically arranged about the longitudinal seam 1301. A sliding groove 302 is provided on the base 3. The sliding groove 302 is an arc structure and is coaxially arranged with the shell 13 and symmetrically arranged about the longitudinal seam 1301. The collection assembly also includes a brush 801, which is arranged on the base 3 and located behind the welding head 5 along the welding direction. The brush surface of the brush 801 is parallel to the longitudinal seam 1301, and the top end of the brush 801 is slidably inserted into the sliding groove 302. When the brush 801 slides along the sliding groove 302, the brush surface of the brush 801 can push the remaining flux on the shell 13 outward in the circumferential direction. To facilitate the driving force for the sliding of the brush 801, the collection assembly also includes a first drive motor. The first drive motor is mounted on the brush 801, and a roller is fixedly sleeved on the motor shaft of the first drive motor. The roller is inserted into the slide groove 302 and makes frictional contact with the side wall of the slide groove 302.

[0047] The base 3 is also equipped with two sorting plates 802, two first collection bins 803, and two second collection bins 804. The two sorting plates 802 are respectively arranged approximately vertically on the two second arc plates 301, located on both sides of the longitudinal seam 1301 and symmetrically arranged about the longitudinal seam 1301. The two sorting plates 802 form a V-shaped structure, with the smaller opening facing backward, which facilitates the guidance of the remaining flux on the housing 13 moved by the brush 801 from back to front. Each sorting plate 802 has multiple sorting holes on its surface, the size of which is equal to a preset size, so that the remaining flux on the housing 13 can be sorted according to different sizes. Each second arc plate 301 has a guide plate 303 on its top. The guide plate 303 is arranged parallel to the second arc plate 301 and located on the outside of the second arc plate 301, and is spaced apart from the second arc plate 301, forming a channel between them. The two first collection bins 803 are respectively arranged on the two arc plates 804. On the second arc plate 301, symmetrically arranged on both sides of the longitudinal seam 1301 and in front of the sorting plate 802, the first collection chamber 803 is located between the guide plate 303 and the second arc plate 301 and is connected to the channel to facilitate the collection of residual flux on the shell 13 smaller than the preset size; two second collection chambers 804 are respectively arranged on the two second arc plates 301, symmetrically arranged on both sides of the longitudinal seam 1301 and in front of the sorting plate 802, the second collection chamber 804 is located in front of the first collection chamber 803 and is connected to the inner front plate surface of the guide plate 303 to facilitate the collection of residual flux on the shell 13 larger than the preset size; there are two suction pumps, respectively located on both sides of the longitudinal seam 1301, with the suction end connected to the two first collection chambers 803 respectively, and the discharge end connected to the top of the second hopper 7 through the conveying pipe 805.

[0048] Initially, the brush 801 is located in the middle of the groove 302.

[0049] During operation, the first drive motor and the suction pump are started simultaneously. The first drive motor drives the roller to rotate. The roller rolls and slides along the slide 302 while making frictional contact with the slide 302, simultaneously driving the brush 801 to slide back and forth along the slide 302. During the sliding of the brush 801, the brush 801 pushes the remaining flux on the housing 13 outward in the circumferential direction. The remaining flux on the housing 13 then moves along the second arc plate 301 to the sorting plate 802, and then moves from back to front along the sorting plate 802 under the action of gravity. The remaining flux on the housing 13 that is smaller than the preset size passes through the sorting hole and enters the channel. Then, under the action of gravity, it slides forward along the channel and then falls into the first collection chamber 803. The remaining flux on the housing 13 that is larger than the preset size moves along the sorting plate 802 to the second collection chamber 804 for collection.

[0050] Under the suction action of the suction pump, the remaining flux on the shell 13, which is smaller than the preset size, in the first collection bin 803 then enters the second hopper 7 through the delivery pipe 805, and then enters the longitudinal seam 1301 through the second discharge port under the action of gravity, ensuring that the remaining flux on the shell 13 collected in the second hopper 7 is of appropriate size, thereby ensuring the subsequent welding quality.

[0051] In a further embodiment, to reduce clogging of the sorting plate 802 and ensure its sorting effect, two connecting rods 806 are provided on the brush 801. The two connecting rods 806 are located on the left and right sides of the brush 801 and are symmetrically arranged about the brush 801. During installation, the middle of both sorting plates 802 are rotated and sleeved on the connecting rods 806. Two racks 807 are provided on the base 3. The two racks 807 are located on both sides of the longitudinal seam 1301 and are symmetrically arranged about the longitudinal seam 1301. The racks 807 are located on the top of the guide plate 303 and are perpendicular to the guide plate 303. A synchronous gear 808 is fixedly provided at the top of the middle of each sorting plate 802. The synchronous gear 808 rotates and sleeves on the connecting rod 806 and meshes with the rack 807.

[0052] During the sliding process of the brush 801 along the slide groove 302, the brush 801 simultaneously drives the sorting plate 802 to slide along the slide groove 302 via the connecting rod 806. On the other hand, through the meshing between the synchronous gear 808 and the rack 807, the brush 801 drives the sorting plate 802 to rotate around its own center. Thus, through the combined motion of the sorting plate 802, it generates vibration, preventing the sorting plate 802 from clogging and ensuring the sorting effect of the sorting plate 802.

[0053] In other embodiments, to improve the accuracy of dispensing the remaining flux on the housing 13, two second partitions 9 are provided on the base 3. The two second partitions 9 are located on both sides of the longitudinal seam 1301 and are symmetrically arranged about the longitudinal seam 1301. The second partitions 9 are strip-shaped structures and extend in a direction parallel to the longitudinal seam 1301, and the plate surface is vertically arranged. The two second partitions 9 are located in the first storage space and form a second storage space between them. The second storage space is located between the second discharge port and the longitudinal seam 1301, and is connected to the second discharge port and the longitudinal seam 1301.

[0054] Thus, under the constraint of the two second partitions 9, the remaining flux on the inner shell 13 of the second hopper 7 can be accurately laid directly above the longitudinal seam 1301, thereby utilizing the residual heat of the remaining flux on the shell 13 to increase the melting efficiency of the flux and ensure the quality and efficiency of welding.

[0055] In other embodiments, after the longitudinal seam 1301 is welded, in addition to the remaining flux, strip-shaped welding slag will also be formed, which requires manual cleaning later, which is troublesome and inefficient.

[0056] Based on this, in the submerged arc welding equipment for the hot-wall hydrogenation reactor provided in this embodiment of the invention, a bucket 10 is also provided on the base 3. The bucket 10 is located behind the welding head 5 along the welding direction and contacts the outer wall of the shell 13, and is used to remove welding slag on the shell 13. The bucket 10 is also located behind the brush 801. In this way, during the movement of the base 3, the welding slag on the shell 13 can be automatically removed by the bucket 10, reducing the trouble of subsequent cleaning steps.

[0057] In a further embodiment, to achieve the collection of welding slag removed by the bucket 10, the guide plate 303 is configured as a V-shaped structure, with the V-shaped tips of the two guide plates 303 facing each other; the base 3 is also provided with two third collection chambers 11, which are respectively arranged on the two second arc plates 301, located on both sides of the longitudinal seam 1301 and symmetrically arranged about the longitudinal seam 1301. The third collection chambers 11 are connected to the rear inner plate surface of the guide plate 303 to facilitate the collection of welding slag on the shell 13.

[0058] In other embodiments, to facilitate the feeding of welding wire, the submerged arc welding equipment for the hot-wall hydrogenation reactor is further configured to include a wire feeding assembly 12. The wire feeding assembly 12 includes a welding wire spool 1201, which is mounted on the base 3 and located behind the welding head 5, with its axis extending horizontally in the left-right direction. The welding wire is wound around the welding wire spool 1201 during installation. The welding wire spool 1201 can rotate around its own axis to facilitate the release or winding of the welding wire. A wire feeding chamber 1202 is also provided on the base 3, located directly above the welding head 5. The top and bottom of the wire feeding chamber 1202 are open to facilitate the passage of the welding wire. A drive gear 1203 and two pairs of driven gears 1204 are inserted into the wire feeding chamber 1202. The drive gear 1203 can rotate around its own axis, and its axis extends horizontally in the left-right direction. The wire feeding chamber 1202 extends horizontally in the left-right direction. A second drive motor is installed outside the wire feeding chamber 1202. The motor shaft of the second drive motor passes through the wire feeding chamber 1202 and is coaxially and fixedly inserted into the drive gear 1203 to facilitate the rotation of the drive gear 1203. The driven wheel 1204 can rotate around its own axis, and the axis extends horizontally in the left-right direction. Two pairs of driven wheels 1204 are arranged vertically at intervals. The two driven wheels 1204 in the same pair are arranged horizontally in the front-back direction at intervals, and are located on the front and back sides of the welding wire respectively, and simultaneously form frictional contact with the welding wire. Each driven wheel 1204 is coaxially and fixedly equipped with a driven gear. The two driven gears on the two driven wheels 1204 in the same pair mesh with each other, and one of the driven gears meshes with the drive gear 1203.

[0059] During use, when it is necessary to pass welding wire to welding head 5, the second drive motor is started. The second drive motor drives the drive gear 1203 to rotate in the forward direction. The drive gear 1203 drives one of the driven gears on the same pair of driven wheels 1204 to rotate in the reverse direction through gear meshing. This driven gear drives its driven wheel 1204 to rotate in the reverse direction, and at the same time drives the other driven gear on the same pair of driven wheels 1204 to rotate in the forward direction through gear meshing. The other driven gear drives its driven wheel 1204 to rotate in the forward direction. Since the two driven wheels 1204 in the same pair rotate in opposite directions, they can synchronously drive the welding wire to be released from the welding wire spool 1201 through frictional engagement, and drive the welding wire spool 1201 to rotate, so that the welding wire can be passed to welding head 5.

[0060] Another embodiment of the present invention provides a submerged arc welding process for a hot-wall hydrogenation reactor, which employs a submerged arc welding device for a hot-wall hydrogenation reactor. The submerged arc welding process for a hot-wall hydrogenation reactor includes the following steps: S1. Place the plug 2 inside the housing 13 and seal the longitudinal seam 1301 from the inside through the plug 2; S2. Place the flux into the first hopper 4; S3, drive the base 3 to slide in a direction parallel to the longitudinal seam 1301, the flux enters the longitudinal seam 1301 through the first discharge port, and under the limitation of the two first partition plates 6, it forms a stacked shape from the inside to the outside. Specifically, the drive cylinder 103 is activated, and its output shaft extends, synchronously driving the first material bin 4 and the welding head 5 to move from back to front. During the movement of the first material bin 4, the flux falls into the longitudinal seam 1301 through the first discharge port under the action of gravity.

[0061] S4, Welding head 5 welds the longitudinal seam 1301 using welding wire and flux.

[0062] 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.

[0063] The above embodiments are merely illustrative of several implementations of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the protection scope of the present invention.

Claims

1. A submerged arc welding device for a hot-wall hydrogenation reactor, characterized in that, The submerged arc welding equipment for hot-wall hydrogenation reactors includes: The blocking frame (2) is located inside the housing (13) and is configured to seal the longitudinal seam (1301) from the inside. The base (3) is located outside the housing (13) and can slide in a direction parallel to the longitudinal seam (1301); The first hopper (4) is set on the machine base (3) and configured to store flux; the first hopper (4) has a first discharge port, which corresponds to and is connected to the longitudinal seam (1301), and the flux can enter the longitudinal seam (1301) through the first discharge port; The welding head (5) is set on the base (3) and located behind the first hopper (4) along the welding direction; the welding head (5) is filled with welding wire; the welding head (5) is configured to weld the longitudinal seam (1301) by welding wire and flux. Two first partitions (6) are set on the machine base (3) and are located on both sides of the longitudinal seam (1301), forming a first storage space of different sizes from the inside to the outside. The first storage space is located between the first discharge port and the longitudinal seam (1301) and is connected to both the first discharge port and the longitudinal seam (1301).

2. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 1, characterized in that, The first partition (6) is a strip structure that extends in a direction parallel to the longitudinal seam (1301) and has a V-shaped cross-section. The V-shaped tips of the two first partitions (6) are arranged opposite each other.

3. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 1, characterized in that, The base (3) is also provided with a second hopper (7), which is located in front of the first hopper (4) along the welding direction and is configured to store the remaining flux on the shell (13). The second hopper (7) is provided with a second discharge port, which corresponds to and communicates with the longitudinal seam (1301). The remaining flux on the shell (13) can enter the longitudinal seam (1301) through the second discharge port. The submerged arc welding equipment for the hot wall hydrogenation reactor also includes a collection component, which is configured to collect the remaining flux on the shell (13) into the second hopper (7).

4. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 3, characterized in that, The collection component includes a suction unit, the suction end of which is connected to the remaining flux on the housing (13), and the discharge end is connected to the second hopper (7).

5. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 4, characterized in that, The collection assembly also includes a brush (801), which is mounted on the base (3) and located behind the welding head (5) along the welding direction. The brush (801) can slide back and forth along the circumference of the housing (13). The brush (801) is configured to move the remaining flux on the housing (13) circumferentially. The base (3) is also provided with two sorting plates (802), two first collection bins (803), and two second collection bins (804). The two sorting plates (802) are located on both sides of the longitudinal seam (1301) and are configured to collect the remaining flux on the housing. (13) The remaining flux is classified according to different sizes; two first collection chambers (803) are located on both sides of the longitudinal seam (1301) and are configured to collect the remaining flux on the shell (13) smaller than the preset size; two second collection chambers (804) are located on both sides of the longitudinal seam (1301) and are configured to collect the remaining flux on the shell (13) larger than the preset size; there are two suction components, located on both sides of the longitudinal seam (1301) and the suction ends are connected to the two first collection chambers (803) respectively.

6. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 5, characterized in that, Two connecting rods (806) are provided on the brush (801), and two sorting plates (802) are respectively rotatably sleeved on the two connecting rods (806); two racks (808) are provided on the base (3), and the two racks (808) are respectively located on both sides of the longitudinal seam (1301); a synchronous gear (809) is fixedly provided on each sorting plate (802), and the synchronous gear (809) is rotatably sleeved on the connecting rod (806) and meshes with the rack (808).

7. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 3, characterized in that, Two second partitions (9) are also provided on the base (3). The two second partitions (9) are located on both sides of the longitudinal seam (1301) and within the first storage space, forming a second storage space between them. The second storage space is located between the second discharge port and the longitudinal seam (1301) and is connected to the second discharge port and the longitudinal seam (1301) at the same time.

8. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 1, characterized in that, The base (3) is also provided with a bucket (10), which is located behind the welding head (5) along the welding direction and is configured to remove welding slag on the housing (13).

9. The submerged arc welding equipment for a hot-wall hydrogenation reactor according to claim 8, characterized in that, Two third collection chambers (11) are also provided on the base (3). The two third collection chambers (11) are located on both sides of the longitudinal seam (1301) and are configured to collect welding slag on the shell (13).

10. A submerged arc welding process for a hot-wall hydrogenation reactor, characterized in that, Using the submerged arc welding equipment for the hot-wall hydrogenation reactor as described in claim 1, the submerged arc welding process for the hot-wall hydrogenation reactor includes the following steps; S1. Place the plug (2) inside the shell (13) and seal the longitudinal seam (1301) from the inside through the plug (2). S2. Place the flux into the first hopper (4); S3, drive the base (3) to slide in a direction parallel to the longitudinal seam (1301), the flux enters the longitudinal seam (1301) through the first discharge port, and under the limitation of the two first partitions (6), it forms a stacked shape from the inside to the outside; S4, Welding head (5) Welds the longitudinal seam (1301) with welding wire and flux.

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