BEST coil box simulation welding device and welding method

Abstract

The invention discloses a BEST coil box simulation welding device which comprises a welding platform, a simulation welding tool and a welding mechanism, the simulation welding tool is arranged on the welding platform and comprises a first simulation part and a second simulation part, the first simulation part is configured to simulate a box body of a BEST coil box, and the second simulation part is configured to simulate a box body of the BEST coil box. The second simulation piece is configured to simulate a cover plate of the BEST coil box, a first opening and a second opening are formed in the first simulation piece, the second opening is arranged towards the first side of the welding platform, and two welding seams are formed between the second simulation piece and the first simulation piece; the welding mechanism comprises a driving assembly and a welding gun, the driving end of the driving assembly is connected with the welding gun, and the driving assembly is configured to drive the welding gun to ascend and descend and move in the length direction of the welding seam. According to the BEST coil box simulation welding device, the simulation welding tool is borne through the welding platform, the real welding working condition of the BEST coil box is reengraved, a reliable test carrier is provided for verification of the welding technology, and the guiding value of test data for actual production is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of nuclear fusion technology, and in particular to a BEST coil box simulation welding device and welding method. Background Technology

[0002] Nuclear fusion energy, as a clean, safe, and inexhaustible energy source, is an important direction for future energy development. Tokamak devices are the mainstream type of device for achieving magnetic confinement fusion, and their core function is to confine high-temperature plasma within a vacuum chamber using a powerful magnetic field. The coil box is a crucial pressure-bearing, load-bearing, and insulating component in a tokamak device, primarily used to house, fix, and protect the toroidal field coils that generate the magnetic field. During operation, the coil box must withstand enormous electromagnetic forces, thermal stresses, and vacuum loads; its structural integrity, dimensional accuracy, and reliability directly affect the safe and stable operation of the entire fusion device.

[0003] Compact fusion energy experimental devices represent the forefront of international fusion research, aiming to achieve fusion plasma combustion in smaller sizes and at lower costs. BEST, as a major compact combustion plasma physics experimental device currently under construction, places far more stringent demands on the performance of its toroidal field coil system than traditional devices. Specifically, to generate a strong magnetic field sufficient to confine the high-temperature plasma, the toroidal field coils of the BEST device must carry extremely high currents, resulting in unprecedented electromagnetic loads on its coil housing components. Simultaneously, to meet the requirements of a compact design, the coil housing structure is more complex and space is more limited, posing severe challenges to its manufacturing precision, material properties, and mechanical stability.

[0004] The compact fusion energy experimental device consists of several welded and fixed units, each including a box and a cover plate welded together. The welding precision requirements between the units are high. During the welding process, the weld seam between the box and the cover plate expands due to heat, resulting in low dimensional stability. This ultimately affects the welding between units, leading to low product yield and high manufacturing costs. Therefore, it is necessary to simulate the welding device using the BEST coil box to find a welding process that meets the overall assembly precision requirements of the device. Summary of the Invention

[0005] To address the related technical problems, the present invention aims to provide a BEST coil box simulation welding device to solve the problem of heat deformation at the weld between the cover plate and the box body; in addition, the present invention also provides a welding method including the above-mentioned BEST coil box simulation welding device.

[0006] To achieve the above objectives, the embodiments of the present invention adopt the following technical solutions: A BEST coil box simulation welding device includes a welding platform, a simulation welding fixture, and a welding mechanism, wherein: The simulated welding fixture is set on the welding platform. The simulated welding fixture includes a first simulated component and a second simulated component. The first simulated component is configured as the box body of the simulated BEST coil box, and the second simulated component is configured as the cover plate of the simulated BEST coil box. The first simulated component has an open first opening at both ends along the first direction, and an open second opening is provided on the top surface of the first simulated component. The second opening is set towards the first side of the welding platform. The second simulated component is set at the second opening and forms two welds extending along the first direction between it and the first simulated component. The welding mechanism is located on the first side of the welding platform. The welding mechanism includes a drive assembly and a welding torch. The drive end of the drive assembly is connected to the welding torch. The drive assembly is configured to drive the welding torch to rise and fall and move along the length of the weld.

[0007] Optionally, the BEST coil box simulation welding device also includes a cooling mechanism, which includes at least two sets of first cooling components, each set of first cooling components corresponding to a weld. The first cooling components are disposed on the first simulation component and close to the corresponding weld. When welding the corresponding weld, the first cooling components are configured to cool the corresponding weld.

[0008] Optionally, the first cooling assembly includes a first arc-shaped tube and several clamping assemblies. The bottom surface of the first arc-shaped tube is open, and both ends of the first arc-shaped tube along its length are provided with first sealing plates. The two first sealing plates are respectively provided with liquid inlet and liquid outlet. A plurality of clamping components are spaced apart along a first direction on the top surface of the second simulation component. The plurality of clamping components are configured to seal and clamp the bottom surface of the first arc-shaped tube body to the top surface of the second simulation component to form a cooling channel for the circulation of cooling medium. The clamping assembly includes a support and a clamping component. The two ends of the support are welded and fixed to the top surface of the second simulation component. The support is located on the periphery of the first arc-shaped tube. The clamping component is vertically mounted on the support component. The clamping component is located directly above the first arc-shaped tube. The clamping component is lowered to a preset height so that the lower end of the clamping component presses against the first arc-shaped tube, thereby sealing and pressing the corresponding part of the first arc-shaped tube against the top surface of the second simulation component. The clamping component includes an adjusting rod with a threaded section, and a threaded hole on the support component. The adjusting rod is vertically mounted in the threaded hole of the support component through the threaded section. The bottom end of the adjusting rod serves as the clamping end, which is equipped with a flexible pad, and the upper end of the adjusting rod is equipped with a handle. A sealing gasket is provided on the top surface of the second simulation component at the location corresponding to the bottom surface of the first arc-shaped tube. The bottom surface of the first arc-shaped tube is sealed to the top surface of the second simulation component through the sealing gasket.

[0009] Optionally, the cooling mechanism also includes two sets of second cooling components, the first set of second cooling components being disposed on the first outer surface of the first simulation component, and the second set of second cooling components being disposed on the second outer surface of the first simulation component; The second cooling assembly includes a second arc-shaped tube disposed on the outer surface of the first simulation element.

[0010] Optionally, the BEST coil box simulation welding device also includes two sets of support assemblies. The first set of support assemblies is attached to the first side of the first simulation component in the second direction, and the second set of support assemblies is attached to the second side of the first simulation component in the second direction, wherein: The support assembly includes a support base, on which a fixing surface corresponding to the first side or the second side of the first simulation component is provided. The support base is provided with a clearance hole, which is configured to press the second cooling component against the first side or the second side of the first simulation component. Both first openings are equipped with second sealing plates. One second sealing plate is equipped with an air inlet pipe, and the other second sealing plate is equipped with an air outlet pipe.

[0011] Optionally, a first bevel and a second bevel are respectively formed on the two welds. The first bevel includes a first longitudinal weld and a second longitudinal weld, and the second bevel includes a third longitudinal weld and a fourth longitudinal weld, wherein: The first longitudinal slit and the third longitudinal slit are respectively set at both ends of the second simulation part along the second direction. The distance between the first longitudinal slit and the second longitudinal slit is a, and the distance between the third longitudinal slit and the fourth longitudinal slit is b, where a is greater than b. The first simulation component has a first straight section and a second straight section inside its opening. A second longitudinal slit is located at the top of the first straight section, and a fourth longitudinal slit is located at the top of the second straight section. The first straight section is inclined to the outside of the first simulation component, and the angle between the first straight section and the vertical direction is between 0.5° and 1.5°. The second straight section is parallel to the vertical direction.

[0012] Optionally, the difference between a and b is between 3mm and 4mm.

[0013] Optionally, the first bevel has a first weld space, and the second bevel has a second weld space; A first protrusion is provided in the first longitudinal seam, and a second protrusion is provided in the second longitudinal seam corresponding to the first protrusion. The first protrusion and the second protrusion divide the first weld seam space into a first welding space and a second welding space. The first protrusion and the second protrusion are spaced apart to form a first welding channel connecting the first welding space and the second welding space. A third boss is provided in the third longitudinal seam, and a fourth boss is provided in the fourth longitudinal seam corresponding to the third boss. The third boss and the fourth boss divide the second weld space into a third welding space and a fourth welding space. The third boss and the fourth boss are spaced apart to form a second welding channel connecting the third welding space and the fourth welding space.

[0014] Optionally, the top of both the first boss and the second boss is provided with a first chamfer with a radius of 3mm, and the bottom of both the first boss and the second boss is provided with a second chamfer with a radius of 2mm. The top of both the third and fourth bosses is provided with a third chamfer, the radius of which is 3mm. The bottom of both the third and fourth bosses is provided with a fourth chamfer, the radius of which is 2mm.

[0015] A welding method, implemented using the aforementioned BEST coil box simulated welding apparatus, includes the following steps: The first simulation component is hoisted onto the welding platform, with the opening of the first simulation component facing the first side of the welding platform; Measurement target mounts are installed on the inner and outer walls of the first and second simulation components; The second simulation component is assembled into the opening of the first simulation component and fixed by spot welding to form a box unit with openings at both ends. The bevel misalignment is required to be ≤2mm and the bevel gap is 2~3mm. Install the second sealing plate at both ends of the box unit and introduce protective gas; After the drive component moves the welding torch to the height corresponding to the first weld seam, it then drives the welding torch to move laterally to weld the first weld seam. After the drive assembly raises and lowers the welding torch to the height corresponding to the second weld seam, it then drives the welding torch to move laterally to perform welding on the second weld seam.

[0016] The beneficial effects of the present invention are as follows: Compared with the prior art, the BEST coil box simulation welding device provided by the present invention has the following beneficial effects: 1. The BEST coil box simulation welding device uses a welding platform to support the simulation welding fixture. The first and second simulation parts of the fixture accurately replicate the structure of the coil box body and cover plate, respectively. The second opening is set facing the first side of the welding platform, providing sufficient space for the operation of the welding mechanism, replicating the real welding conditions of the BEST coil box, providing a reliable test carrier for welding process verification, and ensuring the guiding value of the test data for actual production. 2. Each set of first cooling components corresponds one-to-one with the weld and is set close to the weld. It can directionally cool the weld area during the welding process, quickly remove the heat generated by the welding heat input, effectively reduce the temperature gradient of the weld and heat-affected zone, reduce the risk of welding residual stress and deformation, avoid the dimensional deviation of the simulated parts caused by thermal deformation, and ensure the accuracy of welding simulation data. 3. By combining the first and second cooling components, a comprehensive cooling system for the weld is formed, which can absorb heat simultaneously from the top of the weld and the side wall of the box, further optimize the thermal field distribution of the simulated part, significantly reduce overall welding deformation, and avoid uneven thermal stress distribution caused by single cooling. Attached Figure Description

[0017] To more clearly illustrate and understand the technical solutions in the embodiments of the present invention, the accompanying drawings used in the background technology and embodiment descriptions of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of the present invention and these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of a BEST coil box simulated welding device provided in an embodiment of the present invention; Figure 2 This is a schematic diagram showing the positional relationship between the first arc-shaped tube and the clamping assembly in a BEST coil box simulation welding device provided in an embodiment of the present invention. Figure 3 This is a schematic diagram of the clamping component in a BEST coil box simulated welding device provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of the support component in a BEST coil box simulated welding device provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the first bevel in a BEST coil box simulation welding device provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the second bevel structure in a BEST coil box simulation welding device provided in an embodiment of the present invention; Figure 7 This is a partial enlarged view of the first bevel in a BEST coil box simulation welding device provided in an embodiment of the present invention; Figure 8 This is a partially enlarged view of the second bevel in a BEST coil box simulation welding device provided in an embodiment of the present invention. Detailed Implementation

[0019] The present invention will be further described in detail below with reference to the accompanying drawings.

[0020] To facilitate understanding of the present invention, a more complete description of the invention will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention. It should be noted that when a component is referred to as being "fixed to" another component, it can be directly on the other component or there may be an intermediate component. When a component is referred to as being "connected to" another component, it can be directly connected to the other component or there may be an intermediate component. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementations. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0021] Please see Figures 1 to 8 As shown, this embodiment provides a BEST coil box simulation welding device, which includes a welding platform (not shown in the figure), a simulation welding fixture 10, and a welding mechanism (not shown in the figure). The simulation welding fixture 10 is disposed on the welding platform and includes a first simulation component 11 and a second simulation component 12. The first simulation component 11 is configured to simulate the box body of the BEST coil box, and the second simulation component 12 is configured to simulate the cover plate of the BEST coil box. The first simulation component 11 has open first openings 13 at both ends along a first direction (x direction in the figure), and an open second opening 14 is provided on the top surface of the first simulation component 11. The second opening 14 is disposed facing the first side of the welding platform, and the second simulation component 12 is disposed at the second opening 14 and forms two weld seams 15 extending along the first direction between it and the first simulation component 11. The welding mechanism is disposed on the first side of the welding platform and includes a drive assembly and a welding torch. The drive end of the drive assembly is connected to the welding torch, and the drive assembly is configured to drive the welding torch to rise and fall and move along the length direction of the weld seams 15.

[0022] Specifically, the drive assembly can be a truss-type three-axis module (GTB series), preferably GTB-05.

[0023] As can be seen, the BEST coil box simulation welding device carries the simulation welding fixture 10 on the welding platform. The first and second simulation parts 12 of the fixture accurately replicate the structure of the coil box body and cover plate, respectively. The second opening 14 is set facing the first side of the welding platform, providing sufficient space for the operation of the welding mechanism, replicating the real welding conditions of the BEST coil box, providing a reliable test carrier for welding process verification, and ensuring the guiding value of the test data for actual production.

[0024] In one embodiment, the BEST coil box simulation welding device further includes a cooling mechanism 20, which includes at least two sets of first cooling components 21. Each set of first cooling components 21 corresponds to a weld 15. The first cooling components 21 are disposed on the first simulation component 11 and close to the corresponding weld 15. When welding the corresponding weld 15, the first cooling components 21 are configured to cool the corresponding weld 15.

[0025] As can be seen, each set of first cooling components 21 corresponds one-to-one with each weld 15 and is set close to the weld 15. It can directionally cool the weld 15 area during the welding process, quickly remove the heat generated by the welding heat input, effectively reduce the temperature gradient of the weld 15 and the heat-affected zone, reduce welding residual stress and deformation risk, avoid the dimensional deviation of the simulated parts caused by thermal deformation, and ensure the accuracy of welding simulation data.

[0026] In one embodiment, the first cooling assembly 21 includes a first arc-shaped tube 210 and a plurality of clamping assemblies 211. The bottom surface of the first arc-shaped tube 210 is open, and both ends of the first arc-shaped tube 210 along its length are provided with first sealing plates 217, with inlets and outlets respectively provided on the two first sealing plates 217. The plurality of clamping assemblies 211 are spaced apart along a first direction on the top surface of the second simulation component 12. The plurality of clamping assemblies 211 are configured to seal and clamp the bottom surface of the first arc-shaped tube 210 to the top surface of the second simulation component 12 to form a cooling channel for the circulation of cooling medium. The clamping assembly 211 includes a support member 212 and a clamping member 213. The two ends of the support member 212 are welded to the top surface of the second simulation component 12, and the support member 212 is located on the periphery of the first arc-shaped tube 210. The clamping member 213 is liftable. The clamping member 213 is installed on the support member 212 and is located directly above the first arc-shaped tube 210. The clamping member 213 is lowered to a preset height so that the lower end of the clamping member 213 presses against the first arc-shaped tube 210, thereby sealing and pressing the corresponding part of the first arc-shaped tube 210 against the top surface of the second simulation member 12. The clamping member 213 includes an adjusting rod with a threaded section. The support member 212 has a threaded hole. The adjusting rod is installed in the threaded hole of the support member 212 in a way that allows it to be raised and lowered. The bottom end of the adjusting rod serves as the clamping end and is provided with a flexible pad 214. The upper end of the adjusting rod is provided with a handle 215. A sealing pad 216 is provided on the top surface of the second simulation member 12 at the part corresponding to the bottom surface of the first arc-shaped tube 210. The bottom surface of the first arc-shaped tube 210 is sealed to the top surface of the second simulation member 12 through the sealing pad 216.

[0027] As can be seen, the bottom surface of the first arc-shaped tube 210 of the first cooling component 21 is open, and it is sealed and pressed against the top surface of the second simulation component 12 by the spaced clamping components 211, forming a closed cooling channel to ensure that there is no leakage when the cooling medium circulates and to ensure heat exchange efficiency. The support component 212 of the clamping component 211 is spot-welded and located on the periphery of the tube, which provides a stable installation reference without interfering with the cooling channel. The liftable clamping component 213 can be precisely lifted and lowered by the threaded adjustment rod, and is easy to operate with the handle 215. The clamping force can be adjusted without additional tools to ensure that the tube and the simulation component fit tightly. The flexible pad 214 at the bottom of the adjustment rod can buffer the clamping force to avoid damage to the tube. The sealing pad 216 on the top surface of the second simulation component 12 further enhances the sealing effect. Multiple designs work together to ensure the stability and reliability of the cooling component.

[0028] In one embodiment, the cooling mechanism 20 further includes two sets of second cooling components 22. The first set of second cooling components 22 is disposed on the first outer side surface of the first simulation component 11, and the second set of second cooling components 22 is disposed on the second outer side surface of the first simulation component 11. The second cooling component 22 includes a second arc-shaped tube body disposed on the outer side surface of the first simulation component 11.

[0029] As can be seen, the second cooling component 22 and the first cooling component 21 form an all-round cooling system for the weld 15, which can absorb heat from the top of the weld 15 and the side wall of the box at the same time, further optimize the thermal field distribution of the simulated part, significantly reduce the overall welding deformation, and avoid uneven thermal stress distribution caused by single cooling. The second arc-shaped tube fits the outer contour of the box, increases the heat exchange area, improves the cooling efficiency, and is structurally compatible with the first cooling component 21, which facilitates unified control of cooling parameters and ensures the consistency of cooling effect.

[0030] In one embodiment, the BEST coil box simulation welding device also includes two sets of support components 30. The first set of support components 30 is attached to the first side of the first simulation component 11 in the second direction (y direction in the figure), and the second set of support components 30 is attached to the second side of the first simulation component 11 in the second direction. The support components 30 include a support base, and the support base is provided with a fixing surface 31 corresponding to the first side or the second side of the first simulation component 11. The support base is provided with a clearance hole 32, which is configured to press the second cooling component 22 against the first side or the second side of the first simulation component 11. A second sealing plate 16 is provided at each of the two first openings 13. One second sealing plate 16 is provided with an air inlet pipe, and the other second sealing plate 16 is provided with an air outlet pipe.

[0031] As can be seen, the two sets of support components 30 are set to fit the two sides of the first simulation component 11, and the fixing surface 31 of the support base fits precisely with the side of the simulation component, forming a rigid constraint, which effectively suppresses the lateral deformation of the simulation component during welding and ensures that the deformation data of the simulation test is true and reliable; the clearance hole 32 on the support base can press the second cooling component 22 tightly against the side of the simulation component, ensuring that the arc-shaped tube body fits tightly with the box body, improving the cooling efficiency, without the need for additional pressing components, simplifying the tooling structure; the second sealing plate 16 at the first opening 13, together with the inlet and outlet air pipes, can introduce protective gas into the simulation component and exhaust air and fumes, forming an inert welding atmosphere, preventing oxidation of the molten pool, reducing defects such as porosity and slag inclusions, further improving the quality of the simulated welding, and ensuring the accuracy of the test data.

[0032] In one embodiment, a first bevel 40 and a second bevel 50 are respectively provided on the two welds 15. The first bevel 40 includes a first longitudinal seam 41 and a second longitudinal seam 42, and the second bevel 50 includes a third longitudinal seam 51 and a fourth longitudinal seam 52. The first longitudinal seam 41 and the third longitudinal seam 51 are respectively located at both ends of the second simulation member 12 along the second direction. The distance between the first longitudinal seam 41 and the second longitudinal seam 42 is a, and the distance between the third longitudinal seam 51 and the fourth longitudinal seam 52 is b, where a is greater than b. A first straight section and a second straight section are provided in the opening of the first simulation member 11. The second longitudinal seam 42 is located at the top of the first straight section, and the fourth longitudinal seam 52 is located at the top of the second straight section. The first straight section is inclined to the outside of the first simulation member 11, and the angle between the first straight section and the vertical direction is between 0.5° and 1.5°. The second straight section is arranged parallel to the vertical direction.

[0033] Specifically, the included angle is 1°.

[0034] It is evident that the first and second bevels 50 on the two welds 15 achieve anti-deformation function through differentiated design. The difference in the amount of filler metal in the welds 15 offsets the eccentric force caused by uneven welding thermal shrinkage, thus preventing the overall distortion of the simulated part. The first straight section inside the opening of the first simulated part 11 is inclined outward with the included angle controlled between 0.5° and 1.5°, which can compensate for welding angle deformation in advance. The bevel structure fits the design of the actual coil box weld 15, ensuring that the simulated welding process is highly consistent with the actual production, and providing accurate experimental basis for process optimization.

[0035] In one implementation, the difference between a and b is between 3mm and 4mm.

[0036] It can be seen that limiting the difference between the distance a between the first longitudinal seam 41 and the second longitudinal seam 42 and the distance b between the third longitudinal seam 51 and the fourth longitudinal seam 52 to 3mm-4mm is based on the calculation results of the welding thermal deformation of the BEST coil box. This ensures that the shrinkage stress of the filler metal cancels each other out, avoids insufficient deformation compensation caused by too small a distance difference or local stress concentration caused by too large a distance difference, ensures stable welding quality, and further optimizes the anti-deformation effect.

[0037] In one embodiment, the first bevel 40 has a first weld space, and the second bevel 50 has a second weld space; a first boss 43 is provided in the first longitudinal seam 41, and a second boss 44 is provided in the second longitudinal seam 42 corresponding to the first boss 43. The first boss 43 and the second boss 44 divide the first weld space into a first welding space and a second welding space. The first boss 43 and the second boss 44 are spaced apart to form a first welding channel 45 connecting the first welding space and the second welding space; a third boss 53 is provided in the third longitudinal seam 51, and a fourth boss 54 is provided in the fourth longitudinal seam 52 corresponding to the third boss 53. The third boss 53 and the fourth boss 54 divide the second weld space into a third welding space and a fourth welding space. The third boss 53 and the fourth boss 54 are spaced apart to form a second welding channel 55 connecting the third welding space and the fourth welding space.

[0038] As can be seen, the weld seam 15 space within the first and second bevels 50 provides ample space for welding torch operation and metal filling, ensuring full penetration of the molten pool and avoiding incomplete penetration defects. The first and second bosses 44 divide the first weld seam space into layers, and the third and fourth bosses 54 divide the second weld seam space into layers. The bosses can serve as assembly positioning references, ensuring uniform gaps between simulated parts and improving bevel alignment accuracy. At the same time, they force the use of multi-layer, multi-pass welding processes, reducing single heat input to lower the risk of deformation. The welding channels formed by the boss intervals ensure communication between the upper and lower molten pools, preventing weld seam 15 from becoming disjointed, ensuring the continuity and mechanical properties of the weld seam 15 metal, improving fatigue strength, and optimizing thermal stress distribution through layered design, further suppressing deformation.

[0039] In one embodiment, the top of the first boss 43 and the second boss 44 are both provided with a first chamfer 46, the radius of which is 3mm; the bottom of the first boss 43 and the second boss 44 are both provided with a second chamfer 47, the radius of which is 2mm; the top of the third boss 53 and the fourth boss 54 are both provided with a third chamfer 56, the radius of which is 3mm; the bottom of the third boss 53 and the fourth boss 54 are both provided with a fourth chamfer 57, the radius of which is 2mm.

[0040] As can be seen, the design of the first, second, third, and fourth chamfers can avoid stress concentration at the edge of the boss during welding and prevent cracks from forming after the molten pool cools. The bottom chamfer facilitates the flow and filling of the molten pool metal, ensuring that the root of the boss and the metal of weld 15 are fully fused, improving the connection strength. At the same time, the uniform chamfer specifications standardize the boss structure, reduce processing difficulty, improve the dimensional consistency of mass production, ensure the uniformity of welding process and mechanical properties of the two welds 15, and avoid stress unevenness caused by structural differences.

[0041] A welding method, implemented using the aforementioned BEST coil box simulation welding device, includes the following steps: hoisting a first simulation component 11 onto a welding platform, with the opening of the first simulation component 11 facing the first side of the welding platform; installing measuring target seats on the inner and outer walls of the first simulation component 11 and the second simulation component 12; assembling the second simulation component 12 to the opening of the first simulation component 11 and fixing it by spot welding to form a box unit with openings at both ends, requiring a bevel misalignment ≤2mm and a bevel gap of 2~3mm; installing a second sealing plate 16 at the openings at both ends of the box unit and introducing shielding gas; driving the welding torch to the height corresponding to the first weld seam 15, and then driving the welding torch to move laterally to weld the first weld seam 15; driving the welding torch to rise and fall to the height corresponding to the second weld seam 15, and then driving the welding torch to move laterally to weld the second weld seam 15.

[0042] Specifically, the steps are as follows: a. Perform PT inspection on the bevel surfaces of the first simulated part 11 and the second simulated part 12; b. The first simulated part 11 is hoisted into place with the opening facing the side and the straight section on the side with the reverse deformation at the bottom. The workpiece should not be moved during subsequent assembly, spot welding and subsequent welding. c. Spot weld the measuring target holder to the inner and outer walls of the first simulation part 11 and the second simulation part 12, and weld and remove temporary accessories; d. Assemble the first simulation part 11 and the second simulation part 12 into place and fix them by spot welding. The bevel misalignment should be ≤2mm and the bevel gap should be 2~3mm. e. Install anti-deformation fixtures, back protection fixtures, clamps, and arc-extinguishing plates. The fillet weld 15 between the anti-deformation plate and the workpiece is a staggered intermittent weld 15 with a weld length of 100mm and a gap of 100mm, with a weld leg height ≥15mm; the fillet weld 15 between the anti-deformation partition and the workpiece is a staggered intermittent weld 15 with a weld length of 50mm and a gap of 50mm, with a weld leg height ≥15mm; the fillet weld 15 between the clamp and the workpiece has a weld leg height ≥5mm; first, deposit an isolation layer or use stainless steel sheets for isolation on the contact surface with the product, and then weld and remove temporary accessories; f. Before installing the water-cooled fixture and turning on the cooling water, a pressure leak test should be performed to ensure it passes. The water temperature should be controlled at 6-12 degrees Celsius.

[0043] g. After the oxygen content at the outlet of the protective gas is ≤0.3%, the first root welding is carried out on the longitudinal seam (before the root welding, it is necessary to check whether the anti-deformation tooling is installed as required), and the single-sided welding is double-sided forming. h. Visually inspect and perform penetrant testing on the first root pass, and use an endoscope to check the back-side formation of the root; i. Weld the two longitudinal seams alternately (with shielding gas through the back of the weld 15 with a thickness of less than 5mm), mark the welding direction, and manually apply 3 layers of TIG welding (thickness ≥ 5mm) to each weld 15. Then use automatic TIG filling and covering until the weld is full. During the welding process, grind and clean each layer and each pass, and grind and repair between layers of weld 15. j. During the welding process, deformation should be monitored in real time. The deformation at each position should be ≤2mm. If the deformation exceeds the tolerance, it can be corrected by adjusting the tooling and welding sequence. If there is an adjustment to the welding sequence, detailed change information should be recorded in the record table. k. After all welds are completed, visual inspection, penetration testing, and ultrasonic testing are performed on weld 15.

[0044] In the embodiments disclosed in this invention, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this invention according to the specific circumstances.

[0045] The above embodiments merely illustrate the basic principles and characteristics of the present invention. The present invention is not limited to the above examples. Various changes and modifications can be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A BEST coil box mock weld apparatus, characterized by, The BEST coil box simulation welding device comprises a welding platform, a simulation welding tool and a welding mechanism, wherein: The simulation welding tool is arranged on the welding platform, and comprises a first simulation part and a second simulation part, the first simulation part is configured to simulate a box body of a BEST coil box, the second simulation part is configured to simulate a cover plate of the BEST coil box, two ends of the first simulation part along a first direction are each provided with an open first opening, and a top surface of the first simulation part is provided with an open second opening, the second opening is arranged towards a first side of the welding platform, and the second simulation part is arranged at the second opening and forms two welds extending along the first direction between the first simulation part; The welding mechanism is arranged on the first side of the welding platform, and comprises a driving assembly and a welding gun, a driving end of the driving assembly is connected to the welding gun, and the driving assembly is configured to drive the welding gun to ascend and descend and move along a length direction of the welds.

2. A BEST coil box analog welding device according to claim 1, characterized in that, The BEST coil box simulation welding device further comprises a cooling mechanism, the cooling mechanism comprises at least two sets of first cooling assemblies, each set of the first cooling assembly corresponds to one of the welds, the first cooling assembly is arranged on the first simulation part and close to the corresponding weld, and the first cooling assembly is configured to cool the corresponding weld when welding the corresponding weld.

3. A BEST coil box analog welding device according to claim 2, characterized in that, The first cooling assembly comprises a first arc-shaped pipe body and a plurality of pressing assemblies, a bottom surface of the first arc-shaped pipe body is open, and two ends of the first arc-shaped pipe body along a length direction of the first arc-shaped pipe body are each provided with a first sealing plate, and the two first sealing plates are respectively provided with a liquid inlet and a liquid outlet. The plurality of pressing assemblies are arranged on a top surface of the second simulation part along the first direction, and the plurality of pressing assemblies are configured to seal and press the bottom surface of the first arc-shaped pipe body to be fixed on the top surface of the second simulation part to form a cooling channel for circulation of a cooling medium. The pressing assembly comprises a support and a pressing part, two end points of the support are spot-welded and fixed on the top surface of the second simulation part, and the support is located at an outer periphery of the first arc-shaped pipe body. The pressing part is installed on the support in an ascending and descending manner, the pressing part is located directly above the first arc-shaped pipe body, the pressing part is lowered by a preset height, so that a lower end of the pressing part is pressed against the first arc-shaped pipe body, and then the corresponding part of the first arc-shaped pipe body is sealed and pressed on the top surface of the second simulation part. The pressing part comprises an adjusting rod, the adjusting rod is provided with a threaded section, the support is provided with a threaded hole, and the adjusting rod is installed in the threaded hole of the support in an ascending and descending manner through the threaded section. A bottom end of the adjusting rod serves as a pressing end, the pressing end is provided with a flexible pad, and an upper end of the adjusting rod is provided with a handle. A part of the top surface of the second simulation part corresponding to the bottom surface of the first arc-shaped pipe body is provided with a sealing pad, and the bottom surface of the first arc-shaped pipe body is sealed with the top surface of the second simulation part through the sealing pad.

4. A BEST coil box analog welding device according to claim 2, characterized in that, The cooling mechanism further comprises two sets of second cooling components, the first set of the second cooling components is arranged on the first outer side of the first simulation component, and the second set of the second cooling components is arranged on the second outer side of the first simulation component. The second cooling component comprises a second arc-shaped pipe body arranged on the outer side of the first simulation component.

5. A BEST coil box analog welding device according to claim 4, characterized in that, The BEST coil box simulation welding device further comprises two sets of support components, the first set of the support components is arranged on the first side of the first simulation component in the second direction, and the second set of the support components is arranged on the second side of the first simulation component in the second direction. The support component comprises a support seat, the support seat is provided with a fixing surface corresponding to the first side or the second side of the first simulation component, and the support seat is provided with a relief hole configured to press the second cooling component on the first side or the second side of the first simulation component. Each of the two first openings is provided with a second sealing plate, one of the second sealing plates is provided with an air inlet pipe, and the other of the second sealing plates is provided with an air outlet pipe.

6. A BEST coil box analog welding device according to claim 1, wherein, First and second grooves are arranged on the two weld seams respectively, the first groove comprises first and second longitudinal seams, and the second groove comprises third and fourth longitudinal seams. The first and third longitudinal seams are arranged at the two ends of the second simulation component in the second direction respectively, the distance between the first longitudinal seam and the second longitudinal seam is a, the distance between the third longitudinal seam and the fourth longitudinal seam is b, and the a is greater than the b. The opening of the first simulation component is provided with first and second flat sections, the second longitudinal seam is arranged at the top of the first flat section, and the fourth longitudinal seam is arranged at the top of the second flat section.

7. A BEST coil box analog welding device according to claim 6, characterized in that, The difference between the a and the b is between 3mm and 4mm.

8. A BEST coil box analog welding device according to claim 6, wherein, The first groove has a first weld seam space, and the second groove has a second weld seam space. The first longitudinal seam is provided with a first boss, the second longitudinal seam is provided with a second boss corresponding to the first boss, the first boss and the second boss divide the first weld seam space into a first weld space and a second weld space, and the first boss and the second boss are arranged at intervals to form a first weld channel communicating the first weld space and the second weld space. The third longitudinal seam is provided with a third boss, the fourth longitudinal seam is provided with a fourth boss corresponding to the third boss, the third boss and the fourth boss divide the second weld seam space into a third weld space and a fourth weld space, and the third boss and the fourth boss are arranged at intervals to form a second weld channel communicating the third weld space and the fourth weld space.

9. A BEST coil box analog welding device according to claim 8, characterized in that, The top of the first boss and the second boss is provided with a first chamfer, the radius of the first chamfer is 3mm, the bottom of the first boss and the second boss is provided with a second chamfer, the radius of the second chamfer is 2mm; The top of the third boss and the fourth boss is provided with a third chamfer, the radius of the third chamfer is 3mm, the bottom of the third boss and the fourth boss is provided with a fourth chamfer, the radius of the fourth chamfer is 2mm.

10. A method of welding, characterized by The welding method is implemented by the BEST coil box simulation welding device according to any one of claims 1-9, and the welding method comprises the following steps: The first simulation piece is hoisted on the welding platform, and the opening of the first simulation piece faces the first side of the welding platform; The measuring target seat is installed on the inner and outer walls of the first simulation piece and the second simulation piece; The second simulation piece is assembled to the opening of the first simulation piece and is fixed by spot welding to form a box body unit with two open ends, and the requirement is that the bevel edge offset is less than or equal to 2mm, and the bevel gap is 2-3mm; The second sealing plate is installed at the two open ends of the box body unit, and the protective gas is introduced; The driving assembly drives the welding gun to move to the height corresponding to the first weld, and then drives the welding gun to move horizontally to implement welding on the first weld; The driving assembly drives the welding gun to move to the height corresponding to the second weld, and then drives the welding gun to move horizontally to implement welding on the second weld.

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