Slag removing and grinding device for welding seam of longitudinal welded pipe

Abstract

The invention relates to the technical field of metal pipe machining, in particular to a slag removing and grinding device for a welding seam of a longitudinal welded pipe. According to the technical scheme, the slag removing and grinding device for the welding seam of the longitudinal welded pipe comprises a grinding device body 1, a multi-degree-of-freedom self-adaptive positioning and centering module is arranged on the top face of the grinding device body, and an inner and outer welding seam integrated slag removing and grinding module is arranged on one side of the multi-degree-of-freedom self-adaptive positioning and centering module; a weld quality online detection feedback module is arranged on one face of the inner and outer weld integrated slag removing and grinding module, a closed-loop dust collecting and separating module is arranged in the grinding device body, and an intelligent safety interlocking protection module is arranged on one side of the grinding device body. By means of the multi-degree-of-freedom self-adaptive positioning and centering module, attachment is kept when the pipe diameter changes and the welding seam deviates, the elastic floating support and the universal joint spherical hinge drive the rolling follow-up wheel set to roll along the edge of the welding seam, and the problem that a fixed grinding head cannot adapt to pipe fitting size fluctuation and welding seam deviation is solved.

Description

Technical Field

[0001] This invention relates to the field of metal pipe processing technology, and in particular to a slag removal and grinding device for straight seam welded pipes. Background Technology

[0002] During the production of straight seam welded pipes, defects such as weld slag and burrs will be generated at the weld seam after welding. These defects not only affect the appearance quality of the welded pipe, but also reduce its mechanical properties and corrosion resistance.

[0003] Existing straight seam welded pipe slag cleaning and grinding devices can only process internal or external weld seams separately. Some devices only remove internal burrs with a fixed scraper and cannot process external weld seams at the same time. Other devices focus on cleaning external weld slag but cannot reach into the pipe to grind internal weld seams. This results in the same welded pipe needing to go through multiple devices and multiple clamping to complete the entire process. This not only prolongs the production cycle but also causes uneven weld seam grinding due to the accumulation of positioning errors from multiple times. In addition, most existing devices adopt an open-loop control mode, and the position and pressure of the grinding head cannot be automatically adjusted according to the actual shape of the weld seam. When the pipe diameter fluctuates or the weld seam shifts, it is easy to over-grind and damage the base material or under-grind and leave weld slag. At the same time, most devices lack online quality inspection methods and must rely on manual visual inspection or offline sampling to judge the grinding effect. As a result, defects cannot be detected and corrected in time, and batch rework occurs frequently. Summary of the Invention

[0004] To overcome the limitations of existing straight seam welded pipe slag cleaning and grinding devices that can only handle internal or external weld seams separately, some devices only remove internal burrs with a fixed scraper and cannot handle external weld seams at the same time, while others focus on cleaning external weld slag but cannot reach into the pipe to grind internal weld seams. This results in the same welded pipe needing to go through multiple devices and multiple clamping to complete all the processing, which not only prolongs the production cycle but also causes uneven weld seam grinding due to the accumulation of multiple positioning errors.

[0005] The technical solution of the present invention is as follows: a slag cleaning and grinding device for straight seam welded pipe welds, comprising a grinding device body, a multi-degree-of-freedom adaptive positioning and centering module provided on the top surface of the grinding device body, an integrated slag cleaning and grinding module for inner and outer welds provided on one side of the multi-degree-of-freedom adaptive positioning and centering module, an online weld quality detection and feedback module provided on one side of the integrated slag cleaning and grinding module for inner and outer welds, a closed-loop dust collection and separation module provided inside the grinding device body, and an intelligent safety interlock protection module provided on one side of the grinding device body; Multi-degree-of-freedom adaptive positioning and alignment module: used for precise positioning and follow-up tracking of the grinding head and weld seam; Integrated slag removal and grinding module for internal and external welds: used to perform slag removal and grinding on internal and external welds simultaneously or at different times; Online weld quality inspection and feedback module: used to detect weld grinding quality in real time and provide feedback for adjusting process parameters; Closed-loop dust collection and separation module: used to collect dust and welding slag generated during grinding in real time and perform gas-solid separation; Intelligent safety interlock protection module: used to ensure the safe operation of equipment and the safety of personnel.

[0006] As a preferred embodiment, the multi-degree-of-freedom adaptive positioning and centering module includes: A11: Floating adaptive follow-up centering unit, including elastic floating support, universal joint ball joint and rolling follow-up wheel group, is used to ensure that the grinding head can maintain a precise fit with the weld when the pipe diameter changes and the weld is offset. A12: Automatic weld seam tracking unit, including a laser displacement sensor, a miniature servo electric push rod and an encoder feedback wheel, is used to automatically identify the weld seam position and control the centering mechanism to accurately track along the weld seam direction; A13: Pipe diameter adaptive clamping unit, including V-shaped self-centering chuck, pneumatic clamping cylinder and anti-slip elastic pad, is used to quickly clamp and fix welded pipes of different diameters, so as to keep the pipes stable during processing.

[0007] Preferably, the multi-degree-of-freedom adaptive positioning and centering module includes the following steps when it is in operation: S11: Hoist the straight seam welded pipe to be processed to the center of the V-shaped self-centering chuck at the processing station, and manually pre-adjust the axial position of the pipe to make the weld seam roughly aligned with the center line of the grinding device. S12: Start the pneumatic clamping cylinder to provide clamping force to the V-shaped self-centering chuck. The chuck synchronous linkage drives each jaw to move synchronously towards the center until the anti-slip elastic pad contacts the outer wall of the pipe and reaches the preset clamping force value. S13: Turn on the laser displacement sensor to perform a transverse scan of the weld surface. The sensor collects the offset data of the weld protrusion center relative to the grinding head reference position at a frequency of 200 times per second. S14: The encoder feedback wheel is pressed against the outer wall of the pipe fitting and rotates as the pipe fitting or the grinding device moves, outputting the actual travel speed and position signal of the weld seam to the control system in real time; S15: The control system drives the micro servo electric push rod to move the grinding head bracket laterally according to the lateral offset of the weld detected by the laser displacement sensor, so that the center line of the grinding head is aligned with the center of the weld. S16: The compression spring in the elastic floating bracket pushes the rolling follower wheel assembly to keep it close to both sides of the weld. The guide column restricts the direction of spring deflection, so that the rolling follower wheel assembly always rolls along the edge of the weld. S17: The universal joint ball joint automatically deflects the angle according to the change in weld height, driving the grinding head to oscillate in the X, Y and Z directions with a following angle not exceeding ±15 degrees. S18: The wheel pressure sensor on the rolling follower wheel set continuously monitors the bonding pressure. When the pressure is lower than the set threshold, the control system automatically increases the pre-compression of the compression spring to restore bonding.

[0008] As a preferred option, the integrated slag removal and grinding module for both internal and external welds includes: A21: External weld rough cleaning and grinding unit, including high-speed rotating steel wire brush wheel, carbide scraper and pneumatic impact mechanism, used to initially remove oxide scale, large pieces of weld slag and spatter from the weld surface; A22: External weld seam fine grinding and polishing unit, including belt grinding mechanism, floating pressure grinding plate and grinding fluid spray nozzle, used to finely grind the weld seam after rough grinding to achieve the target surface roughness requirements; A23: Internal weld seam telescopic grinding unit, including telescopic cantilever rod, internal wall grinding head assembly and telescopic drive screw motor, used to extend into the inside of the welded pipe to clean and grind the internal weld seam.

[0009] As a preferred option, the integrated slag removal and grinding module for internal and external welds includes the following steps during operation: S21: The control system sends a start signal, and the high-speed rotating wire brush wheel rotates at a speed of 8000 revolutions per minute. The outer edge of the wire brush wheel reaches a linear speed of 15 meters per second and feeds towards the area to be treated in the weld. S22: The carbide scraper obtains a high-frequency axial impact of 100 times per second through a pneumatic impact mechanism, and the scraper blade cuts into the large weld bead on the outer weld surface of the welded pipe with a depth of 0.5 mm. S23: The external weld rough cleaning and grinding unit moves longitudinally along the weld, with the wire brush wheel and scraper acting alternately on the weld surface. The moving speed is set to 0.5 meters to 1.5 meters per minute and can be manually adjusted according to the pipe diameter. S24: After rough cleaning and rough grinding are completed, the belt grinding mechanism is started, the belt speed is increased to 20 meters per second, and the contact wheel presses against the weld surface with a pressure of 50 Newtons and begins to grind back and forth. S25: The built-in rubber airbag of the floating grinding plate is inflated to 80 kPa pressure, so that the grinding plate can evenly press the sand belt onto the arc surface of the weld and automatically adjust the bonding pressure according to the weld height. S26: The grinding fluid spray nozzle sprays atomized grinding fluid at a flow rate of 10 ml per minute to the grinding contact area, and the atomized particle size is controlled to be below 50 micrometers to uniformly cover the grinding interface. S27: The telescopic drive screw motor rotates in the forward direction to drive the telescopic cantilever rod of the multi-section sleeve structure to extend from the initial position at a speed of 50 mm per second until the inner wall grinding head assembly reaches the starting end of the weld inside the pipe. S28: The cup-shaped grinding wheel in the inner wall grinding head assembly rotates at a speed of 8000 revolutions per minute. The outer edge of the cup-shaped grinding wheel contacts the surface of the weld inside the pipe and moves along the weld direction at a speed of 10 millimeters per second to grind. S29: After the inner weld seam is ground, the telescopic drive screw motor rotates in the opposite direction to fully retract the cantilever rod to the initial position, and the cup-shaped grinding wheel stops rotating and locks in the retracted state.

[0010] As a preferred embodiment, the online weld quality inspection and feedback module includes: A31: Surface roughness online detection unit, including laser triangulation roughness sensor, miniature dustproof cover and temperature compensation probe, is used for non-contact detection of surface roughness of weld after grinding, and to determine whether the grinding quality meets the standard. A32: Excess weld height visual inspection unit, including an industrial linear CCD camera, a coaxial LED ring light source and an image processing industrial control computer, is used to detect whether the excess weld height after grinding meets the process requirements and to prevent excessive or insufficient grinding. A33: Feedback control and process parameter optimization unit, including a programmable logic controller, a human-machine interface touch screen, and a data recording and communication module, used to automatically adjust grinding process parameters based on detection data.

[0011] Preferably, the online weld quality inspection and feedback module includes the following steps when it is in operation: S31: The laser triangulation roughness sensor is installed 50 mm behind the grinding head. It emits a laser beam to the surface of the weld after grinding at a sampling frequency of 100 times per second and receives the reflected light signal. S32: The air curtain interface inside the miniature dustproof cover is connected to compressed air. Compressed air is blown across the transparent window surface at a flow rate of 20 liters per minute to prevent dust from adhering to the sensor lens. S33: The temperature compensation probe is in close contact with the sensor housing to measure the working temperature. When the temperature exceeds 45 degrees Celsius, it outputs a temperature deviation value to the PLC to correct the roughness measurement data. S34: An industrial linear CCD camera continuously scans the weld area at a line frequency of 10,000 lines per second, while a coaxial LED ring light source provides uniform illumination of 5,000 lux to highlight the weld edge contour. S35: The image processing industrial control computer receives 2048-pixel row image data output by the CCD camera and runs a weld contour recognition algorithm to extract the vertical distance between the highest point of the weld reinforcement and the base material plane. S36: The PLC reads the Ra value output by the roughness sensor and the residual height value output by the image processing industrial control computer, and compares the two with the upper and lower limit thresholds pre-stored in the touch screen. S37: When the detected residual height value is greater than the set upper limit, the PLC outputs an instruction to increase the grinding pressure to the electric proportional pressure regulating valve of the belt grinding mechanism, with each adjustment step being 5 Newtons. S38: When the detected Ra value is greater than the set upper limit, the PLC outputs a command to reduce the sanding belt movement speed to the frequency converter of the sanding belt drive motor. The speed reduction step is 2 meters per second each time. S39: After one parameter adjustment, the grinding device processes the same section of weld again, and the detection unit repeats the above measurement steps until the residual height and roughness of all detection points are within the threshold range.

[0012] Preferably, the closed-loop dust collection and separation module includes: A41: Multi-stage negative pressure dust collection unit, including cyclone negative pressure generator, ring dust collection hood and flexible telescopic dust collection tube, is used to generate negative pressure near the grinding point to suck dust and welding slag into the collection system in time. A42: Inertial gravity settling separation unit, including inertial settling chamber, rotary airlock unloading valve and welding slag collection hopper, used to initially separate large particles of welding slag in the gas-solid mixture flow. A43: High-efficiency filtration emission unit, including a pleated cartridge filter, a pulse backflushing cleaning device, and a HEPA high-efficiency filter, is used to finely filter fine dust so that the emission gas meets environmental standards.

[0013] Preferably, the closed-loop dust collection and separation module includes the following steps during operation: S41: Open the main compressed air valve to deliver compressed air with a pressure of 0.5 MPa to the air inlet of the cyclone negative pressure generator. The compressed air rotates at high speed inside the generator to generate a negative pressure with a vacuum degree of not less than 20 kPa. S42: The 270-degree coverage of the circular dust hood is aligned with the contact point between the grinding head and the weld. The negative pressure is transmitted through the flexible telescopic dust suction tube to the inner cavity of the circular dust hood to begin sucking in the dust and welding slag generated during grinding. S43: The gas-solid mixture containing dust and welding slag enters the inertial settling chamber through the dust suction pipe at a speed of 15 meters per second. The mixture impacts the baffle at the entrance of the settling chamber, causing the airflow direction to change by 90 degrees. S44: Weld slag particles larger than 50 micrometers cannot be redirected by the airflow due to inertia and will not impact the inner wall of the settling chamber or fall into the weld slag collection hopper at the bottom. The removal rate of large particles is not less than 85%. S45: The rotary airlock discharge valve automatically rotates 180 degrees every 30 seconds to discharge the welding slag particles accumulated in the welding slag collection hopper to the external waste bucket. During the rotation of the discharge valve, the negative pressure in the settling chamber is maintained to prevent leakage. S46: The dust-laden airflow after removing large particles enters the pleated cartridge filter from the top outlet of the settling chamber. When the airflow passes through the polyester fiber and PTFE membrane layer on the surface of the filter cartridge, dust particles with a diameter greater than 0.3 microns are intercepted. S47: The differential pressure sensor monitors the pressure difference between the inside and outside of the filter cartridge. When the pressure difference reaches 1.5 kPa, the pulse back-flushing cleaning device injects 0.6 MPa of compressed air into the filter cartridge to back-flush the dust layer. S48: The airflow after being filtered by the filter cartridge enters the HEPA high-efficiency filter. The airflow passes evenly through the HEPA filter paper layer at a speed of 0.5 meters per second, completing the interception of more than 99.97% of 0.3-micron particles. S49: Clean airflow is discharged from the HEPA filter outlet into the workshop atmosphere. The dust concentration detector at the exhaust port continuously monitors the emission concentration and uploads the data to the control system.

[0014] As a preferred option, the intelligent safety interlock protection module includes: A51: Overload and overheat protection unit, including current transformer, thermocouple temperature sensor and thermal relay, is used to monitor the operating status of motor and grinding mechanism, and automatically shut down when the limit is exceeded. A52: Dust explosion prevention safety unit, including explosion-proof motor, static grounding device and spark detection and extinguishing device, is used to eliminate the risk of explosion caused by grinding dust and enable the equipment to operate safely in a flammable environment; A53: Emergency stop and alarm unit, including an emergency stop button, a rotating warning light and a buzzer alarm, used to perform an emergency stop and issue an audible and visual alarm in abnormal situations.

[0015] The beneficial effects of this invention are: Existing straight seam welded pipe slag removal and grinding devices can only process internal or external weld seams separately. Some devices only remove internal burrs with a fixed scraper and cannot process external weld seams simultaneously, while others focus on external slag removal but cannot reach inside the pipe to grind internal weld seams. This results in the same welded pipe requiring multiple devices and multiple clamping operations to complete the entire process, which not only prolongs the production cycle but also causes uneven weld seam grinding due to the accumulation of positioning errors. In addition, most existing devices adopt an open-loop control mode, and the position and pressure of the grinding head cannot be automatically adjusted according to the actual weld seam shape. When the pipe diameter fluctuates or the weld seam shifts, it is easy to over-grind and damage the base material or under-grind and leave weld slag residue. At the same time, most devices lack online quality inspection methods and must rely on manual visual inspection or offline sampling to judge the grinding effect, resulting in defects not being detected and corrected in time, and frequent batch rework. This solution uses a multi-degree-of-freedom adaptive positioning and centering module to enable the grinding head to maintain its position when the pipe diameter changes and the weld seam shifts. Precise fit, elastic floating bracket and universal joint ball joint drive the rolling follower wheel set to always roll along the edge of the weld, solving the problem that fixed grinding heads cannot adapt to pipe size fluctuations and weld deviation. The integrated internal and external weld slag cleaning and grinding module integrates three sub-units: external weld rough cleaning and grinding, external weld fine grinding and polishing, and internal weld telescopic grinding. The telescopic cantilever rod sends the cup-shaped grinding wheel into the pipe to treat the internal weld. At the same time, the high-speed steel wire brush wheel and carbide scraper work together to remove oxide scale and weld beads from the external weld, realizing the completion of internal and external weld treatment in the same station, avoiding multiple clamping and repositioning. The weld quality online detection and feedback module measures roughness and excess height non-contactly behind the grinding head. The laser triangulation sensor and linear CCD camera collect data in real time. The programmable logic controller automatically adjusts the grinding pressure and sanding belt speed according to the detection results, forming a closed-loop quality control, which fundamentally solves the problem that open-loop grinding cannot cope with changes in weld morphology, and significantly reduces the probability of over-grinding and under-grinding. Attached Figure Description

[0016] Figure 1 The diagram shown is a first perspective view of the slag removal and grinding device for straight seam welded pipes according to the present invention. Figure 2 The diagram shown is a second perspective view of the slag removal and grinding device for straight seam welded pipes according to the present invention. Figure 3 The diagram shown is a three-dimensional view of the bottom structure of the slag removal and grinding device for straight seam welded pipes according to the present invention. Explanation of reference numerals in the attached drawings: 1. Main body of the grinding device; 2. Multi-degree-of-freedom adaptive positioning and centering module; 3. Integrated slag removal and grinding module for internal and external welds; 4. Online detection and feedback module for weld quality; 5. Closed-loop dust collection and separation module; 6. Intelligent safety interlock protection module. Detailed Implementation

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0018] Please see Figure 1 , Figure 2 and Figure 3 The present invention provides an embodiment: In the high-frequency welded pipe workshop of a straight seam welded pipe manufacturing enterprise, the welded pipes to be processed have an outer diameter of 160 mm, a wall thickness of 6 mm, a length of 6 meters, a weld seam height of about 2 mm, and oxide scale and spattered weld slag on the surface. The traditional processing method requires first hoisting the welded pipe to the outer weld seam grinding station to remove the weld slag on the outer surface, and then transferring it to the inner weld seam processing equipment for inner wall scraping. The two clamping operations cause the weld seam center to shift with a cumulative error of about 0.5 mm. Moreover, the roughness after grinding can only be inspected by manual visual inspection, resulting in a high rework rate. In order to improve the above situation, the workshop introduced the slag removal and grinding device of the present invention. During implementation, the operator hoists the welded pipe to the center of the V-shaped self-centering chuck at the processing station, manually adjusts the axial position of the pipe to make the weld seam roughly aligned with the center line of the grinding device, activates the pneumatic clamping cylinder to provide clamping force to the chuck, and the synchronous connecting rod drives each jaw to move towards the center until the anti-slip elastic pad contacts the outer wall of the pipe and reaches the preset clamping force value. The pipe is then stably fixed. The laser displacement sensor is turned on to perform a transverse scan of the weld seam surface. The sensor collects the offset of the weld seam protrusion center relative to the reference position of the grinding head at high frequency. The encoder feedback wheel is pressed against the outer wall of the pipe and rotates with the movement of the grinding device, outputting the weld seam travel speed and position signals to the control system in real time. The control system drives the micro servo electric push rod to move the grinding head bracket laterally according to the lateral offset of the weld, so that the center line of the grinding head is aligned with the center of the weld. The compression spring in the elastic floating bracket pushes the rolling follower wheel group to keep it close to both sides of the weld. The guide column limits the direction of the spring swing, so that the rolling follower wheel group always rolls along the edge of the weld. The universal joint ball joint automatically deflects the angle according to the change of weld height, causing the grinding head to swing in three directions in space, so that the grinding head always keeps in contact with the weld surface. The wheel pressure sensor on the rolling follower wheel group continuously monitors the contact pressure. When the pressure is lower than the set threshold, the control system automatically increases the pre-compression of the compression spring to restore contact. The integrated slag removal and grinding module for internal and external welds begins operation. The control system sends a start signal, and the high-speed rotating wire brush wheel rotates and feeds towards the area to be treated in the weld. The carbide scraper receives high-frequency axial impact through the pneumatic impact mechanism. The scraper blade cuts into the large weld beads on the surface of the external weld with a set depth of cut. The external weld rough cleaning and grinding unit moves along the longitudinal direction of the weld. The wire brush wheel and scraper act alternately on the weld surface. After rough cleaning and grinding are completed, the belt grinding mechanism starts, the belt linear speed increases to the set value, and the contact wheel presses against the weld surface with constant pressure and begins reciprocating grinding. The rubber air bladder built into the floating pressure grinding plate is inflated, so that the pressure grinding plate presses the belt evenly onto the arc-shaped surface of the weld and automatically adjusts the bonding pressure according to the weld height. The grinding fluid spray nozzle sprays atomized grinding fluid to the grinding contact area at a set flow rate. At the same time, the telescopic drive screw motor rotates in the forward direction to drive the telescopic cantilever rod of the multi-section sleeve structure to extend from the initial position until the inner wall grinding head assembly reaches the starting end of the weld seam inside the pipe. The cup-shaped grinding wheel in the inner wall grinding head assembly rotates, and the outer edge of the cup-shaped grinding wheel contacts the surface of the weld seam inside the pipe and moves along the weld seam direction to grind. After the inner weld seam grinding is completed, the telescopic drive screw motor rotates in the reverse direction to completely retract the cantilever rod back to the initial position. The cup-shaped grinding wheel stops rotating and locks in the retracted state. During the grinding process, the online weld quality detection and feedback module operates synchronously. The laser triangulation roughness sensor is installed behind the grinding head, which emits a laser beam to the ground weld surface at a high frequency and receives the reflected light signal. The air curtain interface inside the miniature dustproof protective cover is connected to compressed air, which blows through the transparent window surface to prevent dust from adhering to the sensor lens. The temperature compensation probe is in close contact with the sensor shell to measure the working temperature. When the temperature exceeds the set value, it outputs the temperature deviation value to the programmable logic controller to correct the roughness measurement data. The industrial linear array CCD camera continuously scans the weld area at a high line frequency. The coaxial LED ring light source provides uniform illumination to highlight the weld edge contour. The image processing industrial control computer receives the image data output by the camera and runs the weld contour recognition algorithm to extract the vertical distance between the highest point of the weld reinforcement and the base material plane. The programmable logic controller (PLC) reads the roughness value output by the roughness sensor and the residual height value output by the image processing industrial control computer, and compares the two with the upper and lower threshold values ​​pre-stored in the touch screen. When the detected residual height value is greater than the set upper limit, the controller outputs an instruction to increase the grinding pressure to the electric proportional pressure regulating valve of the belt grinding mechanism; when the detected roughness value is greater than the set upper limit, the controller outputs an instruction to decrease the belt moving speed to the frequency converter of the belt drive motor. After one parameter adjustment, the grinding device processes the same section of weld again. The detection unit repeats the measurement until the residual height and roughness of all detection points are within the threshold range. The closed-loop dust collection and separation module operates continuously. The main compressed air valve is opened to deliver compressed air to the air inlet of the cyclone negative pressure generator. The compressed air rotates at high speed inside the generator to generate negative pressure. The suction port of the annular dust hood is aligned with the contact point between the grinding head and the weld. The negative pressure is transmitted to the inner cavity of the dust hood through the flexible telescopic suction pipe, sucking in the dust and welding slag generated during grinding. The gas-solid mixture containing dust and welding slag enters the inertial settling chamber along the suction pipe. The mixture hits the baffle at the entrance of the settling chamber, causing the airflow direction to change. Large particles of welding slag cannot be turned with the airflow due to inertia and hit the inner wall of the settling chamber and fall into the welding slag collection hopper at the bottom. The rotating airlock discharge valve rotates at regular intervals to discharge the accumulated welding slag particles to the external waste bucket. During the rotation of the discharge valve, the negative pressure in the settling chamber is maintained without leakage. After removing large particles, the dust-laden airflow enters the pleated cartridge filter from the top outlet of the settling chamber. As the airflow passes through the polyester fiber and polytetrafluoroethylene membrane layer on the surface of the cartridge filter, dust particles larger than 0.3 micrometers in diameter are trapped. The differential pressure sensor monitors the pressure difference between the inside and outside of the cartridge filter. When the pressure difference reaches the set value, the pulse back-flushing cleaning device injects compressed air into the cartridge filter to back-flush the dust layer. The airflow filtered by the cartridge filter enters the high-efficiency air filter. The airflow passes evenly through the filter paper layer to complete the interception of fine particles. The clean airflow is discharged from the outlet of the high-efficiency filter to the workshop atmosphere. The dust concentration detector at the exhaust port continuously monitors the emission concentration and uploads the data to the control system. The intelligent safety interlock protection module monitors the equipment status throughout the process. The current transformer monitors the drive motor current in real time. Thermocouple temperature sensors are installed on the grinding head bearing housing and motor windings to measure the temperature. The thermal relay automatically cuts off the main circuit when the current or temperature exceeds the limit. The explosion-proof motor housing meets the explosion-proof standard. The static electricity grounding device reliably connects the equipment housing to the ground through copper braided straps. The spark detection and extinguishing device includes an infrared spark detector and a high-pressure atomizing nozzle. After detecting a spark, it quickly sprays the extinguishing medium. When the operator presses the emergency stop button or the equipment detects a serious fault, the dual-circuit emergency stop button triggers the equipment to stop running in a very short time. The rotating warning light flashes red and the buzzer alarm sounds at a high decibel to prompt the personnel on site to evacuate or handle the situation. After the entire processing is completed, the operator releases the pneumatic clamping cylinder, removes the processed welded pipe, and enters the next cycle.

[0019] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A slag removal and grinding device for straight seam welded pipes; characterized in that: The device includes a grinding device body (1), a multi-degree-of-freedom adaptive positioning and centering module (2) on the top surface of the grinding device body (1), an integrated internal and external weld seam cleaning and grinding module (3) on one side of the multi-degree-of-freedom adaptive positioning and centering module (2), an online weld seam quality detection and feedback module (4) on one side of the integrated internal and external weld seam cleaning and grinding module (3), a closed-loop dust collection and separation module (5) inside the grinding device body (1), and an intelligent safety interlock protection module (6) on one side of the grinding device body (1). Multi-degree-of-freedom adaptive positioning and centering module (2): used for precise positioning and follow-up tracking of the grinding head and the weld; Integrated slag removal and grinding module for internal and external welds (3): used to perform slag removal and grinding on internal and external welds simultaneously or at different times; Online weld quality inspection and feedback module (4): used to detect weld grinding quality in real time and provide feedback to adjust process parameters; Closed-loop dust collection and separation module (5): used to collect dust and welding slag generated during grinding in real time and perform gas-solid separation; Intelligent safety interlock protection module (6): used to ensure the safe operation of equipment and the safety of personnel.

2. The slag removal and grinding device for straight seam welded pipes according to claim 1, characterized in that: The multi-degree-of-freedom adaptive positioning and centering module (2) includes: A11: Floating adaptive follow-up centering unit, including elastic floating support, universal joint ball joint and rolling follow-up wheel group, is used to ensure that the grinding head can maintain a precise fit with the weld when the pipe diameter changes and the weld is offset. A12: Automatic weld seam tracking unit, including a laser displacement sensor, a miniature servo electric push rod and an encoder feedback wheel, is used to automatically identify the weld seam position and control the centering mechanism to accurately track along the weld seam direction; A13: Pipe diameter adaptive clamping unit, including V-shaped self-centering chuck, pneumatic clamping cylinder and anti-slip elastic pad, is used to quickly clamp and fix welded pipes of different diameters, so as to keep the pipes stable during processing.

3. The slag removal and grinding device for straight seam welded pipes according to claim 2, characterized in that: The multi-degree-of-freedom adaptive positioning and centering module (2) includes the following steps when it is working: S11: Hoist the straight seam welded pipe to be processed to the center of the V-shaped self-centering chuck at the processing station, and manually pre-adjust the axial position of the pipe to make the weld seam roughly aligned with the center line of the grinding device. S12: Start the pneumatic clamping cylinder to provide clamping force to the V-shaped self-centering chuck. The chuck synchronous linkage drives each jaw to move synchronously towards the center until the anti-slip elastic pad contacts the outer wall of the pipe and reaches the preset clamping force value. S13: Turn on the laser displacement sensor to perform a transverse scan of the weld surface. The sensor collects the offset data of the weld protrusion center relative to the grinding head reference position at a frequency of 200 times per second. S14: The encoder feedback wheel is pressed against the outer wall of the pipe fitting and rotates as the pipe fitting or the grinding device moves, outputting the actual travel speed and position signal of the weld seam to the control system in real time; S15: The control system drives the micro servo electric push rod to move the grinding head bracket laterally according to the lateral offset of the weld detected by the laser displacement sensor, so that the center line of the grinding head is aligned with the center of the weld. S16: The compression spring in the elastic floating bracket pushes the rolling follower wheel assembly to keep it close to both sides of the weld. The guide column restricts the direction of spring deflection, so that the rolling follower wheel assembly always rolls along the edge of the weld. S17: The universal joint ball joint automatically deflects the angle according to the change in weld height, driving the grinding head to oscillate in the X, Y and Z directions with a following angle not exceeding ±15 degrees. S18: The wheel pressure sensor on the rolling follower wheel set continuously monitors the bonding pressure. When the pressure is lower than the set threshold, the control system automatically increases the pre-compression of the compression spring to restore bonding.

4. The slag removal and grinding device for straight seam welded pipes according to claim 1, characterized in that: The integrated slag removal and grinding module for internal and external welds (3) includes: A21: External weld rough cleaning and grinding unit, including high-speed rotating steel wire brush wheel, carbide scraper and pneumatic impact mechanism, used to initially remove oxide scale, large pieces of weld slag and spatter from the weld surface; A22: External weld seam fine grinding and polishing unit, including belt grinding mechanism, floating pressure grinding plate and grinding fluid spray nozzle, used to finely grind the weld seam after rough grinding to achieve the target surface roughness requirements; A23: Internal weld seam telescopic grinding unit, including telescopic cantilever rod, internal wall grinding head assembly and telescopic drive screw motor, used to extend into the inside of the welded pipe to clean and grind the internal weld seam.

5. The slag removal and grinding device for straight seam welded pipes according to claim 4, characterized in that: When the integrated internal and external weld seam cleaning and grinding module (3) is working, it includes the following steps: S21: The control system sends a start signal, and the high-speed rotating wire brush wheel rotates at a speed of 8000 revolutions per minute. The outer edge of the wire brush wheel reaches a linear speed of 15 meters per second and feeds towards the area to be treated in the weld. S22: The carbide scraper obtains a high-frequency axial impact of 100 times per second through a pneumatic impact mechanism, and the scraper blade cuts into the large weld bead on the outer weld surface of the welded pipe with a depth of 0.5 mm. S23: The external weld rough cleaning and grinding unit moves longitudinally along the weld, with the wire brush wheel and scraper acting alternately on the weld surface. The moving speed is set to 0.5 meters to 1.5 meters per minute and can be manually adjusted according to the pipe diameter. S24: After rough cleaning and rough grinding are completed, the belt grinding mechanism is started, the belt speed is increased to 20 meters per second, and the contact wheel presses against the weld surface with a pressure of 50 Newtons and begins to grind back and forth. S25: The built-in rubber airbag of the floating grinding plate is inflated to 80 kPa pressure, so that the grinding plate can evenly press the sand belt onto the arc surface of the weld and automatically adjust the bonding pressure according to the weld height. S26: The grinding fluid spray nozzle sprays atomized grinding fluid at a flow rate of 10 ml per minute to the grinding contact area, and the atomized particle size is controlled to be below 50 micrometers to uniformly cover the grinding interface. S27: The telescopic drive screw motor rotates in the forward direction to drive the telescopic cantilever rod of the multi-section sleeve structure to extend from the initial position at a speed of 50 mm per second until the inner wall grinding head assembly reaches the starting end of the weld inside the pipe. S28: The cup-shaped grinding wheel in the inner wall grinding head assembly rotates at a speed of 8000 revolutions per minute. The outer edge of the cup-shaped grinding wheel contacts the surface of the weld inside the pipe and moves along the weld direction at a speed of 10 millimeters per second to grind. S29: After the inner weld seam is ground, the telescopic drive screw motor rotates in the opposite direction to fully retract the cantilever rod to the initial position, and the cup-shaped grinding wheel stops rotating and locks in the retracted state.

6. The slag removal and grinding device for straight seam welded pipes according to claim 1, characterized in that: The online weld quality inspection and feedback module (4) includes: A31: Surface roughness online detection unit, including laser triangulation roughness sensor, miniature dustproof cover and temperature compensation probe, is used for non-contact detection of surface roughness of weld after grinding, and to determine whether the grinding quality meets the standard. A32: Excess weld height visual inspection unit, including an industrial linear CCD camera, a coaxial LED ring light source and an image processing industrial control computer, is used to detect whether the excess weld height after grinding meets the process requirements and to prevent excessive or insufficient grinding. A33: Feedback control and process parameter optimization unit, including a programmable logic controller, a human-machine interface touch screen, and a data recording and communication module, used to automatically adjust grinding process parameters based on detection data.

7. The slag removal and grinding device for straight seam welded pipes according to claim 6, characterized in that: When the online weld quality inspection and feedback module (4) is working, it includes the following steps: S31: The laser triangulation roughness sensor is installed 50 mm behind the grinding head. It emits a laser beam to the surface of the weld after grinding at a sampling frequency of 100 times per second and receives the reflected light signal. S32: The air curtain interface inside the miniature dustproof cover is connected to compressed air. Compressed air is blown across the transparent window surface at a flow rate of 20 liters per minute to prevent dust from adhering to the sensor lens. S33: The temperature compensation probe is in close contact with the sensor housing to measure the working temperature. When the temperature exceeds 45 degrees Celsius, it outputs a temperature deviation value to the PLC to correct the roughness measurement data. S34: An industrial linear CCD camera continuously scans the weld area at a line frequency of 10,000 lines per second, while a coaxial LED ring light source provides uniform illumination of 5,000 lux to highlight the weld edge contour. S35: The image processing industrial control computer receives 2048-pixel row image data output by the CCD camera and runs a weld contour recognition algorithm to extract the vertical distance between the highest point of the weld reinforcement and the base material plane. S36: The PLC reads the Ra value output by the roughness sensor and the residual height value output by the image processing industrial control computer, and compares the two with the upper and lower limit thresholds pre-stored in the touch screen. S37: When the detected residual height value is greater than the set upper limit, the PLC outputs an instruction to increase the grinding pressure to the electric proportional pressure regulating valve of the belt grinding mechanism, with each adjustment step being 5 Newtons. S38: When the detected Ra value is greater than the set upper limit, the PLC outputs a command to reduce the sanding belt movement speed to the frequency converter of the sanding belt drive motor. The speed reduction step is 2 meters per second each time. S39: After one parameter adjustment, the grinding device processes the same section of weld again, and the detection unit repeats the above measurement steps until the residual height and roughness of all detection points are within the threshold range.

8. The slag removal and grinding device for straight seam welded pipes according to claim 1, characterized in that: The closed-loop dust collection and separation module (5) includes: A41: Multi-stage negative pressure dust collection unit, including cyclone negative pressure generator, ring dust collection hood and flexible telescopic dust collection tube, is used to generate negative pressure near the grinding point to suck dust and welding slag into the collection system in time. A42: Inertial gravity settling separation unit, including inertial settling chamber, rotary airlock unloading valve and welding slag collection hopper, used to initially separate large particles of welding slag in the gas-solid mixture flow. A43: High-efficiency filtration emission unit, including a pleated cartridge filter, a pulse backflushing cleaning device, and a HEPA high-efficiency filter, is used to finely filter fine dust so that the emission gas meets environmental standards.

9. The slag removal and grinding device for straight seam welded pipes according to claim 8, characterized in that: When the closed-loop dust collection and separation module (5) is working, it includes the following steps: S41: Open the main compressed air valve to deliver compressed air with a pressure of 0.5 MPa to the air inlet of the cyclone negative pressure generator. The compressed air rotates at high speed inside the generator to generate a negative pressure with a vacuum degree of not less than 20 kPa. S42: The 270-degree coverage of the circular dust hood is aligned with the contact point between the grinding head and the weld. The negative pressure is transmitted through the flexible telescopic dust suction tube to the inner cavity of the circular dust hood to begin sucking in the dust and welding slag generated during grinding. S43: The gas-solid mixture containing dust and welding slag enters the inertial settling chamber through the dust suction pipe at a speed of 15 meters per second. The mixture impacts the baffle at the entrance of the settling chamber, causing the airflow direction to change by 90 degrees. S44: Weld slag particles larger than 50 micrometers cannot be redirected by the airflow due to inertia and will not impact the inner wall of the settling chamber or fall into the weld slag collection hopper at the bottom. The removal rate of large particles is not less than 85%. S45: The rotary airlock discharge valve automatically rotates 180 degrees every 30 seconds to discharge the welding slag particles accumulated in the welding slag collection hopper to the external waste bucket. During the rotation of the discharge valve, the negative pressure in the settling chamber is maintained to prevent leakage. S46: The dust-laden airflow after removing large particles enters the pleated cartridge filter from the top outlet of the settling chamber. When the airflow passes through the polyester fiber and PTFE membrane layer on the surface of the filter cartridge, dust particles with a diameter greater than 0.3 microns are intercepted. S47: The differential pressure sensor monitors the pressure difference between the inside and outside of the filter cartridge. When the pressure difference reaches 1.5 kPa, the pulse back-flushing cleaning device injects 0.6 MPa of compressed air into the filter cartridge to back-flush the dust layer. S48: The airflow after being filtered by the filter cartridge enters the HEPA high-efficiency filter. The airflow passes evenly through the HEPA filter paper layer at a speed of 0.5 meters per second, completing the interception of more than 99.97% of 0.3-micron particles. S49: Clean airflow is discharged from the HEPA filter outlet into the workshop atmosphere. The dust concentration detector at the exhaust port continuously monitors the emission concentration and uploads the data to the control system.

10. The slag removal and grinding device for straight seam welded pipes according to claim 1, characterized in that: The intelligent safety interlock protection module (6) includes: A51: Overload and overheat protection unit, including current transformer, thermocouple temperature sensor and thermal relay, is used to monitor the operating status of motor and grinding mechanism, and automatically shut down when the limit is exceeded. A52: Dust explosion prevention safety unit, including explosion-proof motor, static grounding device and spark detection and extinguishing device, is used to eliminate the risk of explosion caused by grinding dust and enable the equipment to operate safely in a flammable environment; A53: Emergency stop and alarm unit, including an emergency stop button, a rotating warning light and a buzzer alarm, used to perform an emergency stop and issue an audible and visual alarm in abnormal situations.

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