X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system and use method

Abstract

The application relates to an X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system and a use method, wherein the system comprises: a main bearing frame which is a gantry arch structure, and an arc-shaped guide rail is arranged on the main bearing frame; a clamping and positioning mechanism which is arranged on the two sides of the X80 pipeline and is used for positioning the main bearing frame on the two sides of the pipeline; a ring track moving platform which is provided with a first connecting piece at one end, and the ring track moving platform is slidably connected with the main bearing frame through the first connecting piece, so that the circumferential position of the ring track moving platform on the main bearing frame is adjusted; a long-groove-shaped sliding rail is arranged on the ring track moving platform; a multifunctional end effector integrated platform which is slidably connected with the ring track moving platform through a second connecting piece, so that the position of the multifunctional end effector integrated platform in the X direction is adjusted; and an electric arc additive manufacturing module, a surface pretreatment integrated module and a detection scanning module are arranged at the bottom of the multifunctional end effector integrated platform.

Description

Technical Field

[0001] This invention relates to the field of oil and gas pipeline repair technology, specifically to an X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system and its usage method. Background Technology

[0002] As a high-strength long-distance oil and gas pipeline, the X80 pipeline is prone to corrosion, cracks and other damage under harsh working conditions.

[0003] Traditional repair methods require multiple steps involving different equipment: first, the defect is located by inspection equipment; then, it is cleaned manually or with simple equipment; and finally, welding or installation of repair sleeves is performed.

[0004] However, this multi-equipment, multi-process operation mode has the following significant drawbacks: 1. Cumbersome procedures and low efficiency: Switching and positioning between different equipment leads to long operation cycles; 2. Large cumulative error and low precision: Multiple clamping and positioning will introduce errors and affect the repair quality; 3. Low degree of automation: It is highly dependent on manual operation and has poor applicability in harsh field environments.

[0005] Therefore, there is an urgent need for an X80 pipeline additive repair system with highly integrated structure, closed-loop operation process, and precise motion control to solve the above-mentioned technical problems. Summary of the Invention

[0006] To address the aforementioned problems, the primary objective of this invention is to provide an X80 pipeline multi-degree-of-freedom, multi-functional integrated additive repair system that overcomes the shortcomings of existing pipeline repair technologies, such as single equipment function, poor process integration, and insufficient positioning accuracy.

[0007] The second objective of this invention is to provide a method for using the X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides an X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system, comprising: The main load-bearing frame is a gantry arch structure, and an arc-shaped guide rail is provided on the main load-bearing frame; The clamping and positioning mechanism is set on both sides of the X80 pipe to position the main load-bearing frame on both sides of the pipe. A circular track moving platform has a first connector at one end. The circular track moving platform is slidably connected to the main load-bearing frame through the first connector, so that the first connector can slide within the arc-shaped guide rail, thereby adjusting the circumferential position of the circular track moving platform on the main load-bearing frame; the circular track moving platform is provided with a long groove-shaped slide rail. The multi-functional end effector integrated platform is slidably connected to the annular track moving platform via a second connector, so that the second connector slides within the long groove-shaped slide rail, thereby adjusting the position of the multi-functional end effector integrated platform in the X direction; the bottom of the multi-functional end effector integrated platform is provided with an arc additive manufacturing module, a surface pretreatment integrated module, and a detection and scanning module.

[0009] Preferably, in the X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system, the second connector is telescopic to adjust the position of the multi-functional end effector integrated platform in the Y direction.

[0010] The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system, preferably, includes a clamping and positioning mechanism comprising: positioning holes, bases, and bolts; the positioning holes are respectively provided at both ends of the main load-bearing frame; two bases are respectively disposed on both sides of the pipeline; each base includes a counterweight base and connecting lugs, the counterweight base is disposed on the ground, and the two connecting lugs are respectively disposed opposite to each other on the top of the counterweight base; each positioning hole is respectively connected to the corresponding connecting lug by bolts.

[0011] The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system preferably has the following characteristics: the main load-bearing frame has an adjustable span range of 1600-3000mm and a load-bearing capacity of ≥200kg; the clamping and positioning mechanism is suitable for pipe diameter ranges of 610mm-1422mm and has a positioning accuracy of ±0.5mm.

[0012] Preferably, in the X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system, the circular track moving platform has a circumferential movement range of 180° and a repeatability accuracy of ±0.05°.

[0013] The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system, preferably, has a multi-functional end effector integrated platform with three degrees of freedom (X, Y, Z), a load capacity of 25 kg, and a movement range of less than 600 mm in the X direction.

[0014] The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system, preferably, uses CMT cold metal transfer technology in the arc additive manufacturing module, with a power of 5-15kW and a deposition efficiency of 0.5-2kg / h; The surface pretreatment integrated module integrates laser cleaning and coolant spraying functions. The laser cleaning power is 500-1000W, which can pre-clean the repaired surface and cool it after repair. The detection scanning module has a scanning accuracy of ±0.05mm and is equipped with temperature monitoring function.

[0015] The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system, preferably, has an arc-shaped guide rail with a straightness of 0.01mm / 100mm and a service life of ≥100km.

[0016] The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system preferably further includes an intelligent control system, which is electrically connected to the arc additive manufacturing module, the surface pretreatment integrated module, and the detection and scanning module, respectively, and is used to control the operation of the arc additive manufacturing module, the surface pretreatment integrated module, and the detection and scanning module.

[0017] This invention also provides a method for using the X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system, comprising the following steps: Precise positioning and 3D scanning: After the repair system is in place, the detection and scanning module of the multi-functional end effector integrated platform performs defect scanning and 3D modeling, performs high-precision scanning of the pipe surface, and generates a digital 3D model of the defect; Intelligent path planning and positioning: Based on the digital 3D model of the defect, the intelligent control system automatically generates the optimal repair path and drives the circular track moving platform to move circumferentially on the main load-bearing frame, as well as drive the multi-functional end effector integrated platform to move linearly in the X direction on the circular track moving platform and to move linearly in the Z direction under the extension and retraction of the second connecting part, forming a three-degree-of-freedom adjustment of the multi-functional end effector integrated platform to accurately move the multi-functional end effector integrated platform to the starting position of the defect; Laser cleaning pretreatment: The integrated surface pretreatment module, which combines laser cleaning and coolant spraying, is activated to perform non-contact cleaning of defective areas, providing an ideal substrate for additive manufacturing; Additive Repair and Process Control: The electric arc additive manufacturing module is then started and material is deposited according to the predetermined path. During this process, the main load-bearing frame of the gantry arch structure moves in coordination with the circular track moving platform and the multi-functional end effector integrated platform. Through the coordination of multi-axis linear and circumferential rotation, the electric arc additive manufacturing module is always in the best process posture. The process can be monitored in real time to achieve adaptive adjustment of process parameters. Online quality verification and feedback: After the repair is completed, the repair area can be scanned again using the detection and scanning module to perform online quality assessment of size and morphology, forming a closed-loop quality control.

[0018] The present invention has the following advantages due to the adoption of the above technical solutions: (1) High integration of functions and closed-loop operation: The detection, cleaning, repair and verification functions are highly integrated into one terminal, and the entire process operation is completed on a single workstation. This eliminates the time loss and positioning error caused by equipment switching and realizes true integrated intelligent repair of "perception-decision-execution-verification". (2) Precise motion and comprehensive coverage: Combining the multi-degree-of-freedom linear motion of the gantry main load-bearing frame and the 180-degree circumferential rotation capability of the terminal, it can accurately cover a large range of complex curved surfaces of the pipeline, ensuring the optimal position of the repair tool relative to the defect point, and solving the problem of accessibility of complex curved surfaces. (3) High degree of automation and intelligence: It greatly reduces human intervention and is especially suitable for automated operations in harsh environments such as the field and high altitude, significantly improving the safety, efficiency and consistency of repair operations; (4) Modular and maintainable: Each functional unit adopts a modular design and is connected through a standard interface, which facilitates quick replacement, maintenance, upgrade and function expansion, and improves the applicability and service life of the system; In summary, the design of this system significantly improves the intelligence level and engineering quality of X80 pipeline repair, and provides advanced equipment support for the safe operation and maintenance of long-distance oil and gas pipelines. Attached Figure Description

[0019] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts. In the drawings: Figure 1 This is a schematic diagram of the overall structure of the X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system described in this invention; Figure 2 This is a partially enlarged structural schematic diagram of the X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system described in this invention; Figure 3 yes Figure 1 A schematic diagram of the structure of the second connector; Figure 4 This is a schematic diagram of the base structure in this invention.

[0020] The labels for the attached figures are as follows: 1-Main load-bearing frame; 2-Arc-shaped guide rail; 3-Annular track moving platform; 4-First connector; 5-Long slotted slide rail; 6-Multi-functional end effector integrated platform; 7-Second connector; 8-Arc additive manufacturing module; 9-Surface pretreatment integrated module; 10-Detection and scanning module; 11-Positioning hole; 12-Base; 121-Counterweight base; 122-Connecting ear. Detailed Implementation

[0021] Exemplary embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the invention are shown in the drawings, it should be understood that the invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of the invention and to fully convey the scope of the invention to those skilled in the art.

[0022] like Figure 1 and Figure 2 As shown, this invention provides a multi-degree-of-freedom, multi-functional integrated additive repair system for X80 pipelines, comprising: a main load-bearing frame 1, which is a gantry arch structure, with an arc-shaped guide rail 2 on the main load-bearing frame 1; a clamping and positioning mechanism, disposed on both sides of the X80 pipeline, for positioning the main load-bearing frame 1 on both sides of the pipeline; a ring track moving platform 3, one end of which is provided with a first connecting member 4, the ring track moving platform 3 being slidably connected to the main load-bearing frame 1 through the first connecting member 4, so that the first connecting member 4 slides within the arc-shaped guide rail 2, thereby adjusting the circumferential position of the ring track moving platform 3 on the main load-bearing frame 1; a long groove-shaped slide rail 5 on the ring track moving platform 3; a multi-functional end effector integrated platform 6, which is slidably connected to the ring track moving platform 3 through a second connecting member 7, so that the second connecting member 7 slides within the long groove-shaped slide rail 5, thereby adjusting the position of the multi-functional end effector integrated platform 6 in the X direction; and an electric arc additive manufacturing module 8, a surface pretreatment integrated module 9, and a detection and scanning module 10 being disposed at the bottom of the multi-functional end effector integrated platform 6.

[0023] It should be noted that the arc additive manufacturing module 8, the surface pretreatment integration module 9, and the detection and scanning module 10 are all mature components purchased directly from the market, and their specific structures will not be described in detail here.

[0024] In the above embodiments, preferably, as follows: Figure 3 As shown, the second connector 7 is telescopic to adjust the position of the multi-functional end effector integrated platform in the Y direction. Specifically, the second connector 7 can be telescopically operated using an inner rod and an outer rod.

[0025] In the above embodiments, preferably, the clamping and positioning mechanism includes: a positioning hole 11 and a base 12 (see...). Figure 4 The main load-bearing frame 1 has positioning holes 11 at both ends; two bases 12 are respectively located on both sides of the pipe; each base 12 includes a counterweight base 121 and connecting ears 122. The counterweight base 121 is located on the ground, and the two connecting ears 122 are respectively located opposite each other on the top of the counterweight base 121; each positioning hole 11 is connected to the corresponding connecting ear 122 by bolts. Thus, the main load-bearing frame 1 can be fixed.

[0026] In the above embodiments, preferably, the span of the main load-bearing frame 1 is adjustable in the range of 1600-3000mm, and the load-bearing capacity is ≥200kg; the clamping and positioning mechanism is adapted to the pipe diameter range of 610mm-1422mm, and the positioning accuracy is ±0.5mm.

[0027] In the above embodiments, preferably, the circular track moving platform 3 has a circumferential movement range of 180° and a repeatability positioning accuracy of ±0.05°.

[0028] In the above embodiments, preferably, the multi-functional end effector integrated platform 6 has three degrees of freedom: X, Y, and Z, a load capacity of 25 kg, and a movement range of less than 600 mm in the X direction.

[0029] In the above embodiments, preferably, the arc additive manufacturing module 8 adopts CMT cold metal transfer technology with a power of 5-15kW and a deposition efficiency of 0.5-2kg / h; the surface pretreatment integrated module 9 integrates laser cleaning and coolant spraying functions, with a laser cleaning power of 500-1000W, which can pre-clean and cool the repaired surface after repair; the detection scanning module 10 has a scanning accuracy of ±0.05mm and a temperature monitoring function.

[0030] In the above embodiments, preferably, the straightness of the arc-shaped guide rail 2 is 0.01mm / 100mm, and its lifespan is ≥100km.

[0031] In the above embodiments, preferably, the present invention further includes an intelligent control system, which is electrically connected to the arc additive manufacturing module 8, the surface pretreatment integration module 9, and the detection and scanning module 10, respectively, and is used to control the operation of the arc additive manufacturing module 8, the surface pretreatment integration module 9, and the detection and scanning module 10.

[0032] It should be noted that in this invention, the main load-bearing frame, in conjunction with the annular track moving platform and the multi-functional end effector integrated platform, enables the working terminal to perform three-degree-of-freedom adjustments along the pipeline in the X (axial), Y (radial), and Z (vertical) directions. Specifically, the annular track moving platform achieves Y- and Z-direction adjustments when the main load-bearing frame moves circumferentially, the multi-functional end effector integrated platform achieves X-direction adjustments through linear sliding on the annular track moving platform, and the multi-functional end effector integrated platform achieves Z-direction adjustments through the extension and retraction of the second connecting member.

[0033] Among them, the circular track moving platform can rotate up to 180 degrees on the main load-bearing frame, achieving coverage of any position in the pipeline half-section.

[0034] This invention also provides a method for using the X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system, comprising the following steps: Precise positioning and 3D scanning: After the repair system is in place, the detection and scanning module of the multi-functional end effector integrated platform performs defect scanning and 3D modeling, performs high-precision scanning of the pipe surface, and generates a digital 3D model of the defect; Intelligent path planning and positioning: Based on the digital 3D model of the defect, the intelligent control system automatically generates the optimal repair path and drives the circular track moving platform to move circumferentially on the main load-bearing frame, as well as drive the multi-functional end effector integrated platform to move linearly in the X direction on the circular track moving platform and to move linearly in the Z direction under the extension and retraction of the second connecting part, forming a three-degree-of-freedom adjustment of the multi-functional end effector integrated platform to accurately move the multi-functional end effector integrated platform to the starting position of the defect; Laser cleaning pretreatment: The integrated surface pretreatment module, which combines laser cleaning and coolant spraying, is activated to perform non-contact cleaning of defective areas, providing an ideal substrate for additive manufacturing; Additive Repair and Process Control: The electric arc additive manufacturing module is then started and material is deposited according to the predetermined path. During this process, the main load-bearing frame of the gantry arch structure moves in coordination with the circular track moving platform and the multi-functional end effector integrated platform. Through the coordination of multi-axis linear and circumferential rotation, the electric arc additive manufacturing module is always in the best process posture. The process can be monitored in real time to achieve adaptive adjustment of process parameters. Online quality verification and feedback: After the repair is completed, the repair area can be scanned again using the detection and scanning module to perform online quality assessment of size and morphology, forming a closed-loop quality control.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A multi-degree-of-freedom, multi-functional integrated additive repair system for X80 pipelines, characterized in that, include: The main load-bearing frame is a gantry arch structure, and an arc-shaped guide rail is provided on the main load-bearing frame; The clamping and positioning mechanism is set on both sides of the X80 pipe to position the main load-bearing frame on both sides of the pipe. A circular track moving platform has a first connector at one end. The circular track moving platform is slidably connected to the main load-bearing frame through the first connector, so that the first connector can slide within the arc-shaped guide rail, thereby adjusting the circumferential position of the circular track moving platform on the main load-bearing frame; the circular track moving platform is provided with a long groove-shaped slide rail. The multi-functional end effector integrated platform is slidably connected to the annular track moving platform via a second connector, so that the second connector slides within the long groove-shaped slide rail, thereby adjusting the position of the multi-functional end effector integrated platform in the X direction; the bottom of the multi-functional end effector integrated platform is provided with an arc additive manufacturing module, a surface pretreatment integrated module, and a detection and scanning module.

2. The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system according to claim 1, characterized in that, The second connector is retractable to adjust the position of the multi-functional end effector integrated platform in the Y direction.

3. The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system according to claim 1, characterized in that, The clamping and positioning mechanism includes: a positioning hole, a base, and bolts; The positioning holes are respectively provided at both ends of the main load-bearing frame; The two bases are respectively disposed on both sides of the pipe; The base includes a counterweight base and connecting ears. The counterweight base is disposed on the ground, and the two connecting ears are respectively disposed opposite to each other on the top of the counterweight base. Each positioning hole is connected to its corresponding connecting lug by bolts.

4. The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system according to claim 1, characterized in that, The main load-bearing frame has an adjustable span range of 1600-3000mm and a load-bearing capacity of ≥200kg; The clamping and positioning mechanism is suitable for pipe diameters ranging from 610mm to 1422mm, with a positioning accuracy of ±0.5mm.

5. The X80 pipeline multi-degree-of-freedom multi-functional integrated additive repair system according to claim 1, characterized in that, The circular track moving platform has a 180° circumferential movement range and a repeatability accuracy of ±0.05°.

6. The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system according to claim 1, characterized in that, The multi-functional end effector integrated platform has three degrees of freedom: X, Y, and Z, a load capacity of 25 kg, and a movement range of less than 600 mm in the X direction.

7. The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system according to claim 1, characterized in that, The arc additive manufacturing module adopts CMT cold metal transfer technology, with a power of 5-15kW and a deposition efficiency of 0.5-2kg / h; The surface pretreatment integrated module integrates laser cleaning and coolant spraying functions. The laser cleaning power is 500-1000W, which can pre-clean the repaired surface and cool it after repair. The detection scanning module has a scanning accuracy of ±0.05mm and is equipped with temperature monitoring function.

8. The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system according to claim 1, characterized in that, The arc-shaped guide rail has a straightness of 0.01mm / 100mm and a lifespan of ≥100km.

9. The X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system according to claim 1, characterized in that, It also includes an intelligent control system, which is electrically connected to the arc additive manufacturing module, the surface pretreatment integration module, and the detection and scanning module, respectively, and is used to control the operation of the arc additive manufacturing module, the surface pretreatment integration module, and the detection and scanning module.

10. A method of using the X80 pipeline multi-degree-of-freedom multifunctional integrated additive repair system based on any one of claims 1 to 9, characterized in that, Includes the following steps: Precise positioning and 3D scanning: After the repair system is in place, the detection and scanning module of the multi-functional end effector integrated platform performs defect scanning and 3D modeling, performs high-precision scanning of the pipe surface, and generates a digital 3D model of the defect; Intelligent path planning and positioning: Based on the digital 3D model of the defect, the intelligent control system automatically generates the optimal repair path and drives the circular track moving platform to move circumferentially on the main load-bearing frame, as well as drive the multi-functional end effector integrated platform to move linearly in the X direction on the circular track moving platform and to move linearly in the Z direction under the extension and retraction of the second connecting part, forming a three-degree-of-freedom adjustment of the multi-functional end effector integrated platform to accurately move the multi-functional end effector integrated platform to the starting position of the defect; Laser cleaning pretreatment: The integrated surface pretreatment module, which combines laser cleaning and coolant spraying, is activated to perform non-contact cleaning of defective areas, providing an ideal substrate for additive manufacturing; Additive Repair and Process Control: The electric arc additive manufacturing module is then started and material is deposited according to the predetermined path. During this process, the main load-bearing frame of the gantry arch structure moves in coordination with the circular track moving platform and the multi-functional end effector integrated platform. Through the coordination of multi-axis linear and circumferential rotation, the electric arc additive manufacturing module is always in the best process posture. The process can be monitored in real time to achieve adaptive adjustment of process parameters. Online quality verification and feedback: After the repair is completed, the repair area can be scanned again using the detection and scanning module to perform online quality assessment of size and morphology, forming a closed-loop quality control.

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