A visual-based automatic pipe welding device

Abstract

The application discloses a kind of visual-based pipeline automatic welding device, including gear ring, motor with bevel gear, double-row angular contact ball bearing, welding torch adjusting mechanism, wire feeding mechanism, welding torch, depth camera and liquid crystal touch screen.Gear ring can be adapted to different pipe diameter pipeline, motor with bevel gear drives gear ring to drive the whole pipe rotation;Double-row angular contact ball bearing guarantees rotation smooth low friction;Welding torch adjusting mechanism realizes welding torch multidimensional accurate positioning;Wire feeding mechanism stably transports welding wire;Depth camera monitors weld formation and welding quality in real time, picture is transmitted to liquid crystal touch screen synchronously, user can control device operation through display screen.The application can be adapted to multiple specifications pipeline, welding positioning is accurate, quality real-time visual monitoring, solve the problem of traditional pipeline welding efficiency, poor precision, quality difficult monitoring, significantly improve pipeline welding automation level and welding quality, applicable to oil and gas, chemical, municipal and other pipeline welding scene, with good practical value and market prospect.

Description

Technical Field

[0001] This invention relates to the field of pipeline welding equipment technology, and in particular to a vision-based automatic pipeline welding device. Background Technology

[0002] In engineering fields such as oil and gas transportation, chemical pipeline networks, and municipal water supply and drainage, pipeline welding is a crucial process for ensuring the quality of pipeline connections. Traditional pipeline welding often involves manual hand-held welding torches, which suffers from high labor intensity, low efficiency, significant susceptibility to human factors in weld quality, and poor weld consistency. Existing automated pipeline welding equipment generally suffers from poor pipe diameter adaptability, insufficient precision in torch posture adjustment, lack of real-time weld quality monitoring, and unfriendly human-machine interface. For example, some equipment cannot quickly adjust to fit the pipe diameter, while others rely on single-position control, making precise weld tracking difficult. They also exhibit weak adaptability in complex bevel and pipe thickness welding scenarios, failing to meet the demands for efficient, high-precision, and visualized automated welding. Therefore, there is an urgent need for an automated pipeline welding device that can achieve weld recognition and quality monitoring through a vision system, combined with multi-mechanism coordinated motion, to improve the efficiency, accuracy, and stability of pipeline welding. Summary of the Invention

[0003] The purpose of this invention is to provide a vision-based automatic pipeline welding device that uses a depth camera to identify weld seams, track molten pools, and monitor welding quality. Combined with the intuitive operation of an LCD touch screen and the coordinated movement of multiple mechanisms, it solves the problems of poor adaptability, inaccurate positioning, invisible welding quality, and low operating efficiency of existing pipeline welding equipment under complex working conditions.

[0004] To achieve the above objectives, this invention employs a vision-based automatic pipe welding device, comprising a gear ring, a motor with bevel gears, a double-row angular contact ball bearing, a welding torch adjustment mechanism, a wire feeding mechanism, a welding torch, a depth camera, and an LCD touch screen. The welding torch adjustment mechanism includes a perforated coupling, a motor, a slide bar, another perforated coupling, a motor, and a lead screw. The wire feeding mechanism includes a clamping wire feeding wheel, a manual knob, a wire feeding motor, and a wire feeding guide. The gear ring can be fitted onto the outer wall of the pipe and is replaceable according to the pipe diameter. The output end of the motor with bevel gears meshes with the gear ring, driving the entire device to rotate around the pipe. The double-row angular contact ball bearing supports the rotating components, reduces rotational friction, and ensures coaxiality. The depth camera is used to acquire weld images in real time and monitor welding quality and defects. The LCD touch screen displays the depth camera image in real time and controls the device's start / stop, parameter adjustment, and mode switching.

[0005] The gear ring is a detachable and replaceable structure. The gear ring is matched with the corresponding specification according to the outer diameter of the pipe to be welded. The gear ring tooth shape meshes precisely with the output bevel gear of the motor with bevel gear, so as to achieve stable transmission and circumferential motion around the pipe, and adapt to the welding requirements of pipes with different diameters.

[0006] The double-row angular contact ball bearing is sleeved between the pipe and the gear ring, bearing radial and axial loads, reducing rotational resistance, ensuring the stability, coaxiality and motion accuracy of the device when rotating around the pipe, and avoiding welding misalignment.

[0007] In the welding torch adjustment mechanism, a motor drives a lead screw to rotate via a spool coupling, which, in conjunction with a slide bar guide, enables the welding torch to feed and retract in the welding direction. Another motor drives a corresponding transmission component via a spool coupling to finely adjust the height and angle of the welding torch, precisely controlling the relative position of the welding torch and the weld seam to meet the posture requirements of different bevels and welding positions.

[0008] In the wire feeding mechanism, the wire feeding motor drives the clamping wire feeding wheel to rotate, and the manual knob is used to adjust the clamping force. The welding wire is stably fed to the welding position of the welding gun through the wire feeding guide. The wire feeding speed and wire feeding stability can be controlled by the LCD touch screen to ensure the continuous and stable welding process.

[0009] The depth camera captures images of the weld pool, weld formation, and defects in real time. The image processing algorithm analyzes the welding quality in real time and transmits the weld status and defect warning information to the LCD touch screen simultaneously, realizing visual monitoring and quality traceability of the welding process.

[0010] The LCD touch screen has a built-in control unit that displays images captured by the depth camera in real time. It provides an interface for parameter settings, manual / automatic mode switching, welding start / stop, speed adjustment, and welding torch posture adjustment, allowing users to intuitively control and observe the welding status in real time.

[0011] The gear ring, the motor with bevel gears, the double-row angular contact ball bearing, the welding torch adjustment mechanism, the wire feeding mechanism, the depth camera, and the LCD touch screen are electrically and mechanically connected to work together to complete automatic welding and quality monitoring.

[0012] The present invention discloses a vision-based automatic pipe welding device. Under the coordinated control of the overall mechanical structure and electrical system, it realizes weld seam recognition, molten pool tracking and defect detection through a depth camera. Combined with the intuitive operation and parameter adjustment functions of the LCD touch screen, and with the gear ring rotation, precise adjustment of the welding torch and stable wire feeding, it solves the problems of poor adaptability, inaccurate positioning, uncontrollable welding quality and low operation efficiency of existing pipe welding equipment. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This is a schematic diagram of the structure of a vision-based automatic pipe welding device according to the present invention.

[0015] Figure 2 This is a schematic diagram of the welding torch adjustment mechanism of the present invention.

[0016] 1-Gear ring, 2-Motor with bevel gear, 3-Double row angular contact ball bearing, 4-Welding torch adjustment mechanism, 41-Crown coupling, 42-Motor, 43-Slide bar, 44-Crown coupling, 45-Motor, 46-Lead screw, 5-Wire feeding mechanism, 51-Pressure wire feeding wheel, 52-Manual knob, 53-Wire feeding motor, 54-Wire feeding guide tube, 6-Welding torch, 7-Depth camera, 8-LCD touch screen. Detailed Implementation

[0017] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0018] In the description of this invention, it should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, in the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0019] Please see Figures 1 to 2This invention provides a vision-based automatic pipe welding device, comprising a gear ring 1, a motor 2 with bevel gears, a double-row angular contact ball bearing 3, a welding torch adjustment mechanism 4, a wire feeding mechanism 5, a welding torch 6, a depth camera 7, and an LCD touch screen 8. The welding torch adjustment mechanism 4 includes a perforated coupling 41, a motor 42, a slide bar 43, a perforated coupling 44, a motor 45, and a lead screw 46. The wire feeding mechanism 5 includes a clamping wire feeding wheel 51, a manual knob 52, a wire feeding motor 53, and a wire feeding guide tube 54. The gear ring 1 can be fitted onto the outer wall of the pipe and can be replaced and adapted according to the pipe diameter. The output end of the motor 2 with bevel gears meshes with the gear ring 1, driving the entire device to rotate around the pipe. The double-row angular contact ball bearing 3 supports the rotating components, reduces rotational friction, and ensures coaxiality. The depth camera 7 is used to acquire weld images in real time and monitor welding quality and defects. The LCD touch screen 8 is used to display the image from the depth camera 7 in real time and control the device's start / stop, parameter adjustment, and mode switching.

[0020] The gear ring 1 is a detachable and replaceable structure. A gear ring 1 of the corresponding specification is matched according to the outer diameter of the pipe to be welded. The teeth of the gear ring 1 precisely mesh with the output bevel gear of the motor 2, achieving stable transmission and circumferential motion around the pipe, adapting to the welding requirements of pipes with different diameters. The gear ring 1 is reliably positioned relative to the pipe, and disassembly and assembly are convenient, allowing for quick switching between welding different pipe diameters.

[0021] The double-row angular contact ball bearing 3 is sleeved between the pipe and the gear ring 1, bearing radial and axial loads, reducing rotational resistance, ensuring the stability, coaxiality, and motion accuracy of the device when rotating around the pipe, and preventing welding misalignment. The double-row angular contact ball bearing 3 can effectively reduce wear and vibration during rotation, keeping the overall device stable during continuous rotation operation and improving the uniformity of weld formation.

[0022] In the welding torch adjustment mechanism 4, the motor 42 drives the lead screw 46 to rotate via the swivel coupling 41, and guides it with the slide bar 43 to realize the feed and retraction of the welding torch 6 in the welding direction; the motor 45 drives the corresponding transmission components via the swivel coupling 44 to realize the fine adjustment of the height and angle of the welding torch 6, and precisely control the relative position of the welding torch 6 and the weld seam to meet the posture requirements of different bevels and welding positions. The swivel couplings 41 and 44 can buffer the transmission impact, ensure transmission accuracy and running stability, and the slide bar 43 and the lead screw 46 cooperate to achieve high-precision displacement control, so that the welding torch 6 is always aligned with the center of the weld seam.

[0023] In the wire feeding mechanism 5, the wire feeding motor 53 drives the clamping wire feeding wheel 51 to rotate, and the manual knob 52 is used to adjust the clamping force. The welding wire is stably fed to the welding position of the welding torch 6 through the wire feeding guide 54. The wire feeding speed and wire feeding stability can be controlled by the LCD touch screen 8 to ensure a continuous and stable welding process. The clamping wire feeding wheel 51 can prevent the welding wire from slipping, the manual knob 52 allows for quick adjustment of the clamping force on site, and the wire feeding guide 54 provides flexible guidance for the welding wire, avoiding bending and jamming, and ensuring smooth wire feeding.

[0024] The depth camera 7 captures images of the weld pool, weld bead formation, and defects in real time. Image processing algorithms analyze the welding quality in real time, and the weld status and defect warning information are simultaneously transmitted to the LCD touchscreen display 8, enabling visualized monitoring and quality traceability of the welding process. The depth camera 7 has real-time imaging and defect recognition capabilities, quickly identifying common welding defects such as porosity, slag inclusions, incomplete penetration, and undercut, and promptly reporting any abnormal conditions for quick handling by operators.

[0025] The LCD touchscreen display 8 has a built-in control unit that displays the images captured by the depth camera 7 in real time. It provides an interface for parameter settings, manual / automatic mode switching, welding start / stop, speed adjustment, and welding torch posture adjustment, allowing users to intuitively control and observe the welding status in real time. The LCD touchscreen display 8 is simple to operate and provides a clear display, showing key parameters such as welding speed, wire feed speed, and welding torch position in real time. It supports parameter storage and retrieval to adapt to different process requirements.

[0026] The gear ring 1, the motor 2 with bevel gears, the double-row angular contact ball bearing 3, the welding torch adjustment mechanism 4, the wire feeding mechanism 5, the depth camera 7, and the LCD touch screen 8 are electrically and mechanically connected to work together to complete automatic welding and quality monitoring.

[0027] In this embodiment, after the LCD touch screen 8 is powered on, the device enters standby mode. The depth camera 7 acquires initial images of the pipe and weld in real time and transmits the images synchronously to the LCD touch screen 8. The user replaces the gear ring 1 with the corresponding specification according to the diameter of the pipe to be welded and fixes the device to the outer wall of the pipe. The user sets parameters such as welding speed, wire feeding speed, and welding torch posture through the LCD touch screen 8 and selects automatic or manual operation mode.

[0028] After the mode is confirmed, the motor 2 with bevel gear starts, and the output bevel gear meshes with the gear ring 1 to drive the gear ring 1 and the whole device to rotate smoothly around the pipeline. The double-row angular contact ball bearing 3 supports the rotation and reduces friction to ensure the coaxiality of the rotation. The welding torch adjustment mechanism 4 operates according to the preset parameters. The motors 42 and 45 drive the lead screw 46 and related components respectively, and cooperate with the slide bar 43 to complete the feed, height and angle adjustment of the welding torch 6, so that the welding torch 6 is aligned with the weld position. The wire feeding mechanism 5 starts synchronously. The wire feeding motor 53 drives the clamping wire feeding wheel 51 to feed the welding wire. The manual knob 52 adjusts the clamping force. The welding wire is stably fed to the welding torch 6 through the wire feeding guide 54. The welding torch 6 starts the arc and begins the welding operation.

[0029] During welding, the depth camera 7 continuously acquires images of the weld pool and weld bead formation. After processing by an internal algorithm, the weld status and defect information are fed back to the LCD touch screen 8 in real time. Users can observe the welding process in real time through the display and manually intervene and correct parameters when necessary. The control system adjusts the rotation speed, welding torch posture, and wire feed speed in real time based on visual feedback information and preset programs, forming a closed-loop control to ensure welding accuracy and quality stability. After welding is completed, the device automatically stops operating, and users can review the welding process and quality data through the LCD touch screen 8 to complete quality confirmation.

[0030] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A vision-based automatic pipe welding device, characterized in that, The device includes a gear ring, a motor with bevel gears, a double-row angular contact ball bearing, a welding torch adjustment mechanism, a wire feeding mechanism, a welding torch, a depth camera, and an LCD touch screen. The welding torch adjustment mechanism includes a perforated coupling, a motor, a slide bar, a perforated coupling, a motor, and a lead screw. The wire feeding mechanism includes a wire feeding wheel, a manual knob, a wire feeding motor, and a wire feeding guide. The gear ring can be fitted onto the outer wall of the pipe and can be replaced to fit the pipe diameter. The output end of the motor with bevel gears meshes with the gear ring, driving the entire device to rotate around the pipe. The double-row angular contact ball bearing supports the rotating components, reduces rotational friction, and ensures coaxiality. The depth camera is used to acquire weld images in real time and monitor welding quality and defects. The LCD touch screen displays the depth camera image in real time and controls the device's start / stop, parameter adjustment, and mode switching.

2. The vision-based automatic pipe welding device as described in claim 1, characterized in that, The gear ring is a detachable and replaceable structure. The gear ring is matched with the corresponding specification according to the outer diameter of the pipe to be welded. The gear ring tooth shape meshes precisely with the output bevel gear of the motor with bevel gear, so as to achieve stable transmission and circumferential motion around the pipe, and adapt to the welding requirements of pipes with different diameters.

3. The vision-based automatic pipe welding device as described in claim 1, characterized in that, The double-row angular contact ball bearing is sleeved between the pipe and the gear ring, bearing radial and axial loads, reducing rotational resistance, ensuring the stability, coaxiality and motion accuracy of the device when rotating around the pipe, and avoiding welding misalignment.

4. The vision-based automatic pipe welding device as described in claim 1, characterized in that, In the welding torch adjustment mechanism, a motor drives a lead screw to rotate via a spool coupling, which, in conjunction with a slide bar guide, enables the welding torch to feed and retract in the welding direction. Another motor drives a corresponding transmission component via a spool coupling to finely adjust the height and angle of the welding torch, precisely controlling the relative position of the welding torch and the weld seam to meet the posture requirements of different bevels and welding positions.

5. The vision-based automatic pipe welding device as described in claim 1, characterized in that, In the wire feeding mechanism, the wire feeding motor drives the clamping wire feeding wheel to rotate, and the manual knob is used to adjust the clamping force. The welding wire is stably fed to the welding position of the welding gun through the wire feeding guide. The wire feeding speed and wire feeding stability can be controlled by the LCD touch screen to ensure the continuous and stable welding process.

6. The vision-based automatic pipe welding device as described in claim 1, characterized in that, The depth camera captures images of the weld pool, weld formation, and defects in real time. The image processing algorithm analyzes the welding quality in real time and transmits the weld status and defect warning information to the LCD touch screen simultaneously, realizing visual monitoring and quality traceability of the welding process.

7. The vision-based automatic pipe welding device as described in claim 1, characterized in that, The LCD touch screen has a built-in control unit that displays images captured by the depth camera in real time. It provides an interface for parameter settings, manual / automatic mode switching, welding start / stop, speed adjustment, and welding torch posture adjustment, allowing users to intuitively control and observe the welding status in real time.

8. The vision-based automatic pipe welding device as described in claim 1, characterized in that, The gear ring, the motor with bevel gears, the double-row angular contact ball bearing, the welding torch adjustment mechanism, the wire feeding mechanism, the depth camera, and the LCD touch screen are electrically and mechanically connected to work together to complete automatic welding and quality monitoring.

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