A welding device for processing air preheater sealing assembly

Abstract

This invention discloses a welding device for processing air preheater sealing assemblies, relating to the field of air preheater welding technology. The welding device includes a base, a rotor drive assembly, a positioning assembly, a welding assembly, and a control unit. The rotor drive assembly drives the air preheater rotor to rotate. The positioning assembly monitors the welding position on the rotor. The welding assembly includes a transverse welding mechanism and a vertical welding mechanism. The transverse welding mechanism welds the sealing assembly located on the rotor end face radially along the rotor. The vertical welding mechanism welds the sealing assembly located on the rotor side axially along the rotor. The positioning assembly, transverse welding mechanism, and vertical welding mechanism are all connected to the control unit. This invention enables simultaneous welding of both transverse and vertical sealing assemblies on the air preheater rotor, significantly improving welding efficiency.

Description

Technical Field

[0001] This invention relates to the field of air preheater welding technology, and more specifically, to a welding device for processing air preheater sealing components. Background Technology

[0002] An air preheater is a key heat exchange device in a boiler unit of a thermal power plant. It utilizes the waste heat of the flue gas at the boiler tail to heat the air needed for combustion, thereby reducing the exhaust gas temperature and improving the boiler's thermal efficiency. Rotary air preheaters are widely used in large and medium-sized thermal power units due to their compact structure and high heat exchange efficiency. Their core component is a rotor equipped with heat transfer elements. The rotor rotates continuously during operation, with its upper and lower halves located in the flue gas and air circulation zones, respectively. Heat exchange is achieved through the periodic absorption and release of heat by heat storage elements.

[0003] Sealing performance directly determines the leakage rate of a rotary air preheater and is a core indicator for evaluating its operational quality. The air preheater's sealing system mainly includes radial seals, axial seals, and bypass seals. Radial seal assemblies are installed on the upper and lower end faces of the rotor to seal the dynamic gap between the rotor end face and the fixed sector plate; axial seal assemblies are installed on the cylindrical side of the rotor to seal the dynamic gap between the rotor side and the outer casing. The installation accuracy and welding quality of these two types of seal assemblies directly determine the air preheater's leakage rate, thus affecting the unit's thermal efficiency and operational economy.

[0004] Currently, the air preheater sealing assembly is mainly installed by welding the sealing plates to the rotor body. However, existing welding equipment and processes have the following significant shortcomings: Existing welding equipment can only perform horizontal or vertical welding independently, making simultaneous operation impossible. Since the radial sealing assembly is located on the rotor end face with its weld seam distributed radially, while the axial sealing assembly is located on the rotor side with its weld seam extending axially, the two are in different spatial orientations. Existing equipment can only weld sealing components in one direction, requiring horizontal and vertical welding to be performed separately, resulting in a lengthy welding process. Specifically, after completing the radial seal welding on one end face, the welding equipment must be re-clamped or its orientation adjusted before the axial seal welding can be performed. This process of equipment adjustment and workpiece turnaround consumes a significant amount of time, severely restricting production efficiency. Summary of the Invention

[0005] The purpose of this invention is to provide a welding equipment for processing air preheater sealing components, which can simultaneously weld the transverse sealing components and the vertical sealing components on the air preheater rotor, greatly improving welding efficiency.

[0006] The embodiments of the present invention are implemented as follows: This application provides a welding device for processing air preheater sealing components, including: Base; Rotor drive assembly for driving the rotor of the air preheater to rotate; A positioning component for monitoring the welding position on the rotor; The welding assembly includes a transverse welding mechanism and a vertical welding mechanism. The transverse welding mechanism is used to weld a sealing assembly located on the rotor end face along the radial direction of the rotor, and the vertical welding mechanism is used to weld a sealing assembly located on the rotor side along the axial direction of the rotor. The control unit is connected to the positioning component, the horizontal welding mechanism, and the vertical welding mechanism.

[0007] In some embodiments of the present invention, the above-mentioned vertical welding mechanism includes a first vertical moving part, at least one first horizontal moving part, and at least one first welding head. The first vertical moving part is disposed on the base, and the moving end of the first vertical moving part moves along the axial direction of the rotor. The first horizontal moving parts are all disposed at the moving ends of the first vertical moving parts, and the moving ends of the first horizontal moving parts all move in a direction perpendicular to the axis of the rotor. The first welding heads are disposed one-to-one on the moving ends of the first horizontal moving parts. A first rotating part is disposed between each first welding head and the moving end of the corresponding first horizontal moving part for adjusting the angle of the first welding head.

[0008] In some embodiments of the present invention, the first vertical moving part includes a vertical rail, a first lead screw, and a first slider. The vertical rail is disposed on the base, and the extending direction of the vertical rail is parallel to the axial direction of the rotor. The first slider is slidably disposed on the vertical rail along the extending direction of the vertical rail. The first lead screw is rotatably disposed on the vertical rail and is parallel to the extending direction of the vertical rail. The first lead screw passes through the first slider and is threadedly engaged with the first slider. The first slider is the moving end of the first vertical moving part. One end of the first lead screw is connected to a first drive motor for driving its rotation. The first drive motor is connected to the control unit.

[0009] In some embodiments of the present invention, the above-mentioned transverse welding mechanism includes a second transverse moving part, at least one second vertical moving part, and at least one second welding head. The second transverse moving part is disposed at the free end of the vertical rail, and the moving end of the second transverse moving part moves radially along the rotor. The second vertical moving part is disposed at the moving end of the second transverse moving part, and the moving end of the second vertical moving part moves in a direction parallel to the axis of the rotor. The second welding heads are correspondingly disposed on the moving ends of the second vertical moving parts. A second rotating part is disposed between each second welding head and the moving end of the corresponding second vertical moving part for adjusting the angle of the second welding head.

[0010] In some embodiments of the present invention, the second lateral moving part includes a horizontal rail, a second lead screw, and a second slider. The horizontal rail is arranged radially along the rotor, and one end of the horizontal rail is connected to the free end of the vertical rail. The second slider is slidably disposed on the horizontal rail along the extension direction of the horizontal rail. The second lead screw is rotatably disposed on the horizontal rail and parallel to the extension direction of the horizontal rail. The second lead screw passes through the second slider and is threadedly engaged with the second slider. The second slider is the moving end of the second lateral moving part. One end of the second lead screw is connected to a second drive motor for driving its rotation. The second drive motor is connected to the control unit.

[0011] In some embodiments of the present invention, a rotating seat is provided between the vertical rail and the base. The rotating seat is rotatably mounted on the base. The vertical rail is connected to the rotating seat and can rotate with the rotating seat. The rotating seat is provided with a locking mechanism for locking the rotating seat to the base.

[0012] In some embodiments of the present invention, the rotor drive assembly includes a third drive motor connected to the rotor of the air preheater for driving the rotor to rotate.

[0013] In some embodiments of the present invention, the positioning component includes a vertical position sensor and a horizontal position sensor. The vertical position sensor is used to monitor the vertical position information of the weld, and the horizontal position sensor is used to monitor the horizontal position information of the weld. Both the vertical position sensor and the horizontal position sensor are connected to the control unit.

[0014] Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects: This invention integrates a horizontal welding mechanism and a vertical welding mechanism within the same equipment. A rotor drive assembly rotates the rotor to the horizontal and vertical welding mechanisms, and a positioning component continuously monitors the welding position of the sealing components at these locations. This allows the rotor drive assembly to stop rotating, ensuring the rotor precisely aligns with the weld seam of the corresponding sealing component at each mechanism before welding. This combines the previously separate radial and axial sealing welding processes into a single operation, completed synchronously within the same rotor rotation cycle. Compared to the existing technology that involves first welding the end face and then re-clamping for side welding, this solution eliminates the time consumed by equipment adjustment, workpiece turnover, and secondary clamping, effectively improving welding efficiency. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a three-dimensional structural diagram of an embodiment of the present invention in one direction; Figure 2 for Figure 1 Enlarged view of point A in the middle; Figure 3 for Figure 1 Enlarged view of point B in the middle; Figure 4 This is a three-dimensional structural diagram of an embodiment of the present invention in another direction; Figure 5 for Figure 4 Enlarged view of point C in the middle; Figure 6 for Figure 4 Enlarged view of point D in the middle; Figure 7 This is a schematic diagram of a three-dimensional cross-sectional structure according to an embodiment of the present invention; Figure 8 for Figure 7 Enlarged view at point E in the middle; Figure 9 for Figure 7 Enlarged view at point F; Figure 10 This is a schematic diagram of the installation structure of the welding assembly in an embodiment of the present invention; Figure 11 This is a schematic diagram of the installation structure of the positioning component in an embodiment of the present invention.

[0017] Icons: 1-Base; 2-Rotor; 3-Third drive motor; 401-Vertical position sensor; 402-Horizontal position sensor; 501-Horizontal rail; 502-Second lead screw; 503-Second slider; 504-Second drive motor; 6-Second vertical moving part; 7-Second welding head; 8-Second rotating part; 901-Vertical rail; 902-First lead screw; 903-First slider; 904-First drive motor; 10-First horizontal moving part; 11-First welding head; 12-First rotating part; 13-Control unit; 14-Rotating seat; 15-Locking mechanism; 16-Drive mechanism. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0020] Example Please refer to Figures 1-11 This embodiment provides a welding device for processing air preheater sealing assemblies, including a base 1, a rotor 2 drive assembly, a positioning assembly, a welding assembly, and a control unit 13. The rotor 2 drive assembly drives the rotor 2 of the air preheater to rotate. The positioning assembly monitors the welding position on the rotor 2. The welding assembly includes a transverse welding mechanism and a vertical welding mechanism. The transverse welding mechanism is used to weld the sealing assembly located on the end face of the rotor 2 radially. The vertical welding mechanism is used to weld the sealing assembly located on the side of the rotor 2 axially. The positioning assembly, the transverse welding mechanism, and the vertical welding mechanism are all connected to the control unit 13.

[0021] In this embodiment, the rotor 2 has a vertical weld seam corresponding to each transverse weld seam. This means that obtaining the position information of the transverse weld seams naturally yields the position information of the vertical weld seams. During operation, the air preheater rotor 2 to be welded is first installed at the equipment station, and the rotor 2 drive assembly is connected to the rotor 2. Simultaneously, the transverse welding mechanism and the vertical welding mechanism are pre-fixed on the base 1 at positions corresponding to the welding stations on the end face and side of the rotor 2, respectively. The fixed position information (including their spatial coordinates in the transverse and vertical directions) of each of the transverse and vertical welding mechanisms is pre-determined and stored in the control unit 13. Subsequently, the positioning component is activated, continuously monitoring the spatial position information of each weld seam on the rotor 2 within its detection range, including the real-time coordinates in the transverse and vertical directions of the transverse weld seam (radial sealing weld seam) located on the end face of the rotor 2 and the vertical weld seam (axial sealing weld seam) located on the side of the rotor 2. Based on the weld position information fed back in real time by the positioning component, the control unit 13 drives the rotor 2 drive assembly to rotate the rotor 2. During this process, the positioning component continuously acquires the lateral position information of each lateral weld on the end face of the rotor 2 and compares this real-time lateral position information with the lateral position information of the pre-stored lateral welding mechanism. When the lateral position information of a certain lateral weld matches the lateral position information of the lateral welding mechanism, it indicates that the lateral weld has accurately reached the position of the lateral welding mechanism in the lateral direction. The control unit 13 then controls the rotor 2 drive assembly to stop rotating and activates the locking mechanism 15 to self-lock the rotor 2 at that angular position. At this time, the lateral welding mechanism and the lateral weld are completely aligned in the lateral direction. After the rotor 2 stops rotating and self-locks, since the lateral welds on the end face of the rotor 2 and the vertical welds on the side of the rotor 2 are spatially distributed at 90° and correspond one-to-one with the same angular position of the rotor 2, the vertical welds located at the same angular position as the lateral welds are naturally vertically aligned with the vertical welding mechanism in the vertical direction. The precise alignment stage then begins: Control unit 13 drives the transverse welding mechanism to move vertically. During this vertical movement, the positioning component continuously monitors the vertical position information of the transverse weld and compares it in real time with the pre-stored vertical position information of the transverse welding mechanism. When the vertical position information of the transverse weld matches the vertical position information of the transverse welding mechanism, control unit 13 immediately stops the vertical movement of the transverse welding mechanism. At this point, the transverse welding mechanism and the transverse weld are also fully aligned vertically, and the transverse weld is fully aligned. Simultaneously, as the transverse welding mechanism completes... After the transverse weld is aligned laterally, the control unit 13 drives the vertical welding mechanism to move laterally. During the lateral movement, the positioning component continuously monitors the lateral position information of the vertical weld that is at the same angle as the transverse weld and compares it with the lateral position information of the pre-stored vertical welding mechanism in real time. When the lateral position information of the vertical weld matches the lateral position information of the vertical welding mechanism at a certain moment, the control unit 13 immediately stops the lateral movement of the vertical welding mechanism. At this time, the vertical welding mechanism and the vertical weld are also fully aligned laterally, and the vertical weld is fully aligned.

[0022] Once the positioning component confirms that the transverse welding mechanism is fully aligned with the transverse weld and the vertical welding mechanism is fully aligned with the vertical weld, the control unit 13 simultaneously activates both the transverse and vertical welding mechanisms. The transverse welding mechanism welds radially along the extension direction of the transverse weld, i.e., the rotor 2, while the vertical welding mechanism welds axially along the extension direction of the vertical weld, i.e., the rotor 2, completing the synchronous welding operation of the transverse and vertical welds at the current angular position. After the current two welds are completed, the control unit 13 releases the rotor 2 from locking and drives the rotor 2 to continue rotating to the next angular position, so that the next transverse weld reaches the position of the transverse welding mechanism. The cycle of transverse coarse alignment, rotor 2 stopping self-locking, vertical fine alignment (for the transverse welding mechanism), transverse fine alignment (for the vertical welding mechanism), and synchronous welding is repeated until all sealing component welds are completed.

[0023] In this embodiment, the transverse weld (radial sealing weld) on the end face of the air preheater rotor 2 extends radially along the rotor 2, and the vertical weld (axial sealing weld) on the side of the rotor 2 extends axially along the rotor 2. Both are distributed in mutually perpendicular spatial planes, but in the circumferential direction of the rotor 2, each angular position corresponds to both a transverse weld and a vertical weld, with a one-to-one mapping relationship on the circumferential coordinates of the rotor 2. This embodiment fully utilizes this geometric feature, using the rotor 2 drive assembly as the coarse positioning actuator for the weld along the circumferential direction. Through the stepping rotation of the rotor 2, each transverse weld sequentially reaches the angular position of the transverse welding mechanism pre-fixed at the end face station, completing the transverse alignment of the transverse weld. Since the circumferential positions of the transverse weld and the vertical weld correspond one-to-one, when the rotor 2 stops at a certain angle, the vertical weld corresponding to that angular position naturally aligns vertically with the vertical welding mechanism pre-fixed at the side station.

[0024] Based on this, the horizontal welding mechanism only needs to make minor fine adjustments in the vertical direction to achieve vertical alignment with the horizontal weld, and the vertical welding mechanism only needs to make minor fine adjustments in the horizontal direction to achieve horizontal alignment with the vertical weld. The entire process forms a four-step alignment strategy: rotor 2 rotation achieves coarse horizontal alignment, rotor 2 stopping achieves natural vertical alignment, horizontal welding mechanism vertical fine adjustment achieves fine horizontal alignment, and vertical welding mechanism horizontal fine adjustment achieves fine vertical alignment. Among them, the positioning component undertakes the core function of real-time monitoring and feedback throughout the entire process. It continuously acquires the position coordinates of each weld in both the horizontal and vertical dimensions. The control unit 13 uses the pre-stored fixed position information of each welding mechanism as a reference to perform closed-loop control on the rotation angle of rotor 2, the vertical displacement of the horizontal welding mechanism, and the horizontal displacement of the vertical welding mechanism. Each movement step uses the matching of the position information fed back by the positioning component with the target position information as the basis for determining the termination of the action, ensuring that the accuracy of each alignment step meets the welding process requirements.

[0025] Compared with existing technologies, this embodiment achieves automatic identification and precise alignment of welds by pre-fixing the horizontal and vertical welding mechanisms to corresponding positions on the base 1, and cooperating with the positioning components to monitor and provide feedback on the horizontal and vertical positions of each weld in real time. The entire alignment and welding process is fully automated and requires no manual intervention. The horizontal welding mechanism only requires vertical single-degree-of-freedom fine adjustment, and the vertical welding mechanism only requires horizontal single-degree-of-freedom fine adjustment to complete the precise alignment. The equipment structure is simple, the control difficulty is low, and the manufacturing cost is low. Welding is performed after the rotor 2 stops and self-locks, which fundamentally avoids the impact of vibration and positioning deviation during rotation on the welding quality, resulting in stable and reliable welding quality. More importantly, horizontal welding and vertical welding are completed synchronously and in parallel within the same rotor 2 stop cycle. Unlike existing technologies, which require completing end face welding first and then re-clamping for side welding, this embodiment combines two processes that originally needed to be completed in steps and sequences into one process, eliminating the time consumption of equipment adjustment, workpiece turnover, and secondary clamping, and effectively improving welding efficiency.

[0026] This embodiment also achieves automatic alignment of the horizontal weld and the vertical weld in the horizontal direction, automatic fine adjustment of the horizontal weld in the vertical direction, natural alignment of the vertical weld and the vertical weld in the vertical direction, and automatic fine adjustment of the vertical weld in the horizontal direction by pre-fixing and storing the position information of the horizontal weld and the vertical weld in the vertical direction, combined with the real-time monitoring and feedback of the horizontal and vertical positions of each weld by the positioning component. The entire alignment process is fully automated, without the need for manual measurement and intervention, which greatly improves the alignment efficiency and accuracy and reduces the technical threshold for operators.

[0027] Meanwhile, in this embodiment, the horizontal welding mechanism only needs to perform a single degree of freedom fine adjustment in the vertical direction to complete the alignment of the horizontal weld seam, and the vertical welding mechanism only needs to perform a single degree of freedom fine adjustment in the horizontal direction to complete the alignment of the vertical weld seam. Compared with the technical embodiment that requires complex three-dimensional spatial positioning, this embodiment decomposes the alignment motion into rotor 2 rotation (horizontal coarse alignment) and welding head unidirectional fine adjustment (fine alignment). The motion degree of freedom configuration of each actuator is extremely simplified, which significantly reduces the complexity of the equipment structure and the development difficulty of the control system. At the same time, it reduces the accumulation of errors caused by the motion links, which is conducive to improving the stability and reliability of the system operation.

[0028] Since the precision alignment of each welding mechanism and subsequent welding operations are only carried out after the rotor 2 stops and self-locks, the fine adjustment process of the horizontal welding mechanism and the vertical welding mechanism, as well as the welding process, are all completed in the state of absolute stillness of the rotor 2. This fundamentally eliminates the adverse effects of the rotor 2's rotational inertia, speed fluctuation and roundness error on alignment accuracy and welding quality in traditional continuous rotation welding. It ensures that the relative position between the welding head and the weld seam remains constant during the welding process, which is conducive to obtaining high-quality weld seams with consistent penetration and uniform shape.

[0029] In this embodiment, the one-to-one correspondence between the transverse weld and the vertical weld in the circumferential angle of the rotor 2 is cleverly utilized. When the rotor 2 stops and self-locks to align a certain transverse weld with the transverse welding mechanism in the transverse direction, the vertical weld at the same angle as the transverse weld naturally completes the alignment with the vertical welding mechanism in the vertical direction. This eliminates the independent positioning process of the vertical welding mechanism in the vertical direction, reduces the number of motion axes and adjustment time of the vertical welding mechanism, and further simplifies the equipment structure and control process.

[0030] During the rotor 2 stop cycle, the horizontal welding mechanism and the vertical welding mechanism complete their respective alignment and perform welding operations synchronously. This combines the horizontal sealing welding and vertical sealing welding, which originally needed to be completed in steps and sequences, into a single process that is completed in parallel. This significantly increases the amount of welding work per unit time and significantly shortens the total welding time of the entire air preheater sealing assembly. At the same time, the two welding mechanisms work and finish at the same time, which helps to control the heat symmetry of rotor 2 during the welding process, reduce welding deformation caused by uneven heat input, and further improve the installation accuracy of the sealing assembly.

[0031] Furthermore, in this embodiment, the vertical welding mechanism includes a first vertical moving part, at least one first horizontal moving part 10, and at least one first welding head 11. The first vertical moving part is disposed on the base 1, and the moving end of the first vertical moving part moves along the axial direction of the rotor 2. The first horizontal moving parts 10 are all disposed on the moving ends of the first vertical moving parts, and the moving ends of the first horizontal moving parts 10 all move in a direction perpendicular to the axis of the rotor 2. The first welding heads 11 are correspondingly disposed on the moving ends of the first horizontal moving parts 10. A first rotating part 12 is disposed between each first welding head 11 and the moving end of the corresponding first horizontal moving part 10 for adjusting the angle of the first welding head 11.

[0032] The aforementioned vertical welding mechanism is fixed to the base 1 at the welding station on the side of the rotor 2. Its fixed position information (including axial position and lateral position perpendicular to the axis) is pre-determined and stored in the control unit 13. When the rotor 2 rotates stepwise to a certain angle position under the drive of the rotor 2 drive assembly and locks itself, the positioning assembly monitors the spatial coordinates of the vertical weld at that angle position on the side of the rotor 2 in real time. Since the vertical weld is naturally aligned with the axial position of the vertical welding mechanism after the rotor 2 stops, the control unit 13 only needs to drive the first vertical moving part for axial fine adjustment. The positioning assembly provides real-time feedback on the axial position of the vertical weld. When this position matches the pre-stored axial position of the vertical welding mechanism, the axial movement stops, completing the axial alignment. Subsequently, the control unit 13 drives the first lateral moving part 10 to move in the direction perpendicular to the axis of the rotor 2 (i.e., radially). The positioning assembly monitors the radial position of the vertical weld in real time. When this radial position matches the pre-stored radial position of the vertical welding mechanism, the radial movement stops, completing the radial alignment.

[0033] Based on the above, the control unit 13 adjusts the angle of the first welding head 11 through the first rotating part 12, ensuring that its axial direction is precisely aligned with the extension direction of the vertical weld seam, thus ensuring that the angle of the welding torch relative to the weld seam meets the welding process requirements. After completing the above three-dimensional alignment, the control unit 13 starts the first welding head 11 to perform welding, while simultaneously driving the first vertical moving part to continuously feed the welding head along the extension direction (axial direction) of the vertical weld seam, completing the welding of the entire weld seam. When the vertical welding mechanism includes multiple first transverse moving parts 10 and multiple first welding heads 11, each welding head is independently driven by its corresponding first transverse moving part 10 and adjusted radially, allowing for simultaneous welding of multiple vertical weld seams at different axial heights on the side of the rotor 2 within the same stop cycle, further improving efficiency.

[0034] In this embodiment, the vertical weld seams on the side of the rotor 2 of the air preheater extend along the axial direction of the rotor 2 and are distributed at different circumferential angles and axial heights on the side of the rotor 2. This solution provides displacement along the axial direction of the rotor 2 through the first vertical moving part, enabling the welding head to reach any axial height; it provides radial displacement along the rotor 2 through the first lateral moving part 10, enabling the welding head to approach or move away from the side of the rotor 2, adapting to the welding requirements of rotors 2 with different diameters and compensating for the roundness error of the rotor 2; and it adjusts the angle of the welding head through the first rotating part 12, ensuring that the welding torch is aligned with the weld seam in the optimal posture. The three moving parts work together under the unified scheduling of the control unit 13, using the pre-stored fixed position of the vertical welding mechanism as a reference, combined with the real-time position information fed back by the positioning component, to complete axial alignment, radial alignment, and angular alignment in sequence, ultimately enabling the welding head to be precisely aligned with the vertical weld seam in the position and posture, completing high-quality welding while the rotor 2 is stationary.

[0035] Furthermore, in this embodiment, the aforementioned first vertical moving part includes a vertical rail 901, a first lead screw 902, and a first slider 903. The vertical rail 901 is disposed on the base 1, and the extending direction of the vertical rail 901 is parallel to the axial direction of the rotor 2. The first slider 903 is slidably disposed on the vertical rail 901 along the extending direction of the vertical rail 901, and the first lead screw 902 is rotatably disposed on the vertical rail 901 and is parallel to the extending direction of the vertical rail 901. The first lead screw 902 passes through the first slider 903 and is threadedly engaged with the first slider 903, which is the moving end of the first vertical moving part. One end of the first lead screw 902 is connected to a first drive motor 904 for driving its rotation, and the first drive motor 904 is connected to the control unit 13.

[0036] The control unit 13 calculates the target displacement required for the first slider 903 based on the real-time axial position information of the vertical weld seam fed back by the positioning component and the pre-stored axial position information of the vertical welding mechanism, and sends a motion command to the first drive motor 904. Upon receiving the command, the first drive motor 904 starts rotating, driving the first lead screw 902 to rotate synchronously. Since the first slider 903 is sleeved on the first lead screw 902 and the two are threaded together, and the first slider 903 is simultaneously constrained circumferentially by the vertical rail 901 and can only slide along the direction of the vertical rail 901, the rotational motion of the first lead screw 902 is converted into linear motion of the first slider 903 along the extension direction of the vertical rail 901 (i.e., the axial direction of the rotor 2) through the threaded pair. During the slider movement, the positioning component continuously monitors the real-time axial position of the vertical weld seam and feeds it back to the control unit 13. The control unit 13 compares the real-time position with the target position, and when they match, immediately sends a stop command to the first drive motor 904. The motor stops, and the first slider 903 stops precisely at the target position, completing the axial alignment. During the welding process, the control unit 13 also drives the first lead screw 902 to rotate continuously via the first drive motor 904, causing the first slider 903 to drive the first transverse moving part 10 and the first welding head 11 to feed at a uniform speed along the axial direction, completing the continuous welding of the vertical weld. When it is necessary to adjust the welding head angle or make radial adjustments, the first slider 903 remains locked in the current position, providing a stable axial reference for the welding head.

[0037] This embodiment employs a transmission structure combining a lead screw and a slider, efficiently converting the rotational motion of the motor into the linear motion of the slider. This results in high transmission efficiency and fast response, enabling rapid axial positioning and smooth feeding of the first slider 903. The lead screw drive boasts extremely high transmission precision; by controlling the motor's rotation angle, the slider's displacement can be precisely controlled. Combined with real-time feedback from the positioning component, micron-level precise positioning can be achieved, ensuring the first welding head 11 is accurately aligned with the vertical weld seam, effectively guaranteeing welding quality. The vertical rail 901 provides rigid guiding support for the slider, allowing it to maintain a stable trajectory even under welding loads. Its strong resistance to eccentric loading ensures the straightness and stability of the welding torch movement during welding, contributing to a weld seam with uniform penetration and consistent shape. The lead screw thread pair has a self-locking characteristic; when the motor stops rotating, the slider automatically locks at its current position, maintaining positional stability without the need for an additional braking device. This simplifies the equipment structure, reduces manufacturing costs, and prevents weld head offset caused by accidental slider slippage during welding.

[0038] Furthermore, in this embodiment, the aforementioned transverse welding mechanism includes a second transverse moving part, at least one second vertical moving part 6, and at least one second welding head 7. The second transverse moving part is disposed at the free end of the vertical rail 901, and the moving end of the second transverse moving part moves radially along the rotor 2. The second vertical moving part 6 is disposed at the moving end of the second transverse moving part, and the moving end of the second vertical moving part 6 moves in a direction parallel to the axis of the rotor 2. The second welding heads 7 are correspondingly disposed on the moving ends of the second vertical moving parts 6, and a second rotating part 8 is disposed between each second welding head 7 and the corresponding moving end of the second vertical moving part 6 for adjusting the angle of the second welding head 7.

[0039] In this embodiment, the transverse welding mechanism is fixed at the position of the free end of the vertical rail 901 corresponding to the welding station on the end face of the rotor 2, and its fixed position information is pre-stored in the control unit 13. The rotor 2 driving assembly drives the rotor 2 to rotate stepwise, and the positioning assembly continuously monitors the transverse position of the transverse weld on the end face of the rotor 2. When the transverse position of a certain transverse weld matches the transverse position of the transverse welding mechanism, the rotor 2 stops rotating and self-locks. At this time, the transverse welding mechanism and the transverse weld have been aligned in the transverse direction. Then, the fine alignment stage begins. The control unit 13 drives the second vertical moving part 6 to move axially, and the positioning assembly monitors the vertical position of the transverse weld in real time. When the vertical position matches the pre-stored vertical position of the transverse welding mechanism, the axial movement stops, and the vertical fine alignment is completed. Next, the control unit 13 adjusts the angle of the second welding head 7 through the second rotating part 8 to precisely align its axial direction with the extension direction (radial) of the transverse weld, ensuring that the welding torch tilt angle meets the welding process requirements. After alignment, the control unit 13 activates the second welding head 7 to perform welding, while simultaneously driving the second transverse moving part to continuously feed the welding head radially along the extension direction of the transverse weld, i.e., the rotor 2, to complete the welding of the entire transverse weld. When the transverse welding mechanism includes multiple second vertical moving parts 6 and multiple second welding heads 7, each welding head can simultaneously weld multiple transverse welds at different radial positions on the end face within the same rotor 2 stop cycle, further improving efficiency.

[0040] In the above process, this embodiment, through the combined configuration of the second transverse moving part and the second vertical moving part 6, enables the transverse welding mechanism to be freely positioned in both the radial and axial dimensions of the rotor 2, accommodating air preheater rotors 2 with different diameters and end face heights, thus exhibiting strong versatility. A second rotating part 8 is provided between the second welding head 7 and the second vertical moving part 6, giving the welding head angle adjustment capability. This allows for adjustment of the welding torch posture according to the bevel angle of the transverse weld, ensuring the welding torch is aligned with the weld at the optimal angle, which is beneficial for obtaining high-quality end face welds. The transverse welding mechanism is fixed to the free end of the vertical rail 901, sharing the vertical rail 901 structure with the vertical welding mechanism. The overall structure is compact and rationally laid out, reducing the equipment's footprint. When the transverse welding mechanism includes multiple welding heads, each welding head shares the radial movement provided by the second transverse moving part and performs axial adjustment through an independent second vertical moving part 6. This allows for simultaneous welding of multiple transverse welds at different radial positions on the rotor 2 end face within the same stop cycle, significantly improving welding efficiency.

[0041] Furthermore, in this embodiment, the second lateral moving part includes a horizontal rail 501, a second lead screw 502, and a second slider 503. The horizontal rail 501 is arranged radially along the rotor 2, and one end of the horizontal rail 501 is connected to the free end of the vertical rail 901. The second slider 503 is slidably disposed on the horizontal rail 501 along its extension direction. The second lead screw 502 is rotatably disposed on the horizontal rail 501 and is parallel to its extension direction. The second lead screw 502 passes through the second slider 503 and is threadedly engaged with the second slider 503. The second slider 503 is the moving end of the second lateral moving part, and one end of the second lead screw 502 is connected to a second drive motor 504 for driving its rotation. The second drive motor 504 is connected to the control unit 13.

[0042] In this embodiment, after the transverse welding mechanism has completed the transverse rough alignment of the transverse weld (i.e., the transverse weld is located at the radial position of the transverse rail 501 after the rotor 2 stops), the control unit 13 calculates the target displacement required by the second slider 503 based on the radial position information of the transverse weld fed back by the positioning component in real time, and sends a motion command to the second drive motor 504. The second drive motor 504 starts to rotate and drives the second lead screw 502 to rotate synchronously. Since the second slider 503 is sleeved on the second lead screw 502 and the two are threaded together, and the second slider 503 is constrained by the circumferential direction of the transverse rail 501 and can only slide along the direction of the transverse rail 501, the rotational motion of the second lead screw 502 is converted into linear motion of the second slider 503 along the extension direction of the transverse rail 501, i.e., the radial direction of the rotor 2, through the threaded pair. During the movement of the second slider 503, the positioning component continuously monitors the real-time radial position of the transverse weld and feeds it back to the control unit 13. The control unit 13 compares the real-time position with the target position. When the two match, it immediately sends a stop command to the second drive motor 504. The motor stops, and the second slider 503 stops precisely at the target position, completing the radial alignment. During the welding process, the control unit 13 drives the second lead screw 502 to rotate continuously through the second drive motor 504, causing the second slider 503 to drive the second vertical moving part 6 and the second welding head 7 to feed radially at a uniform speed along the extension direction of the transverse weld, i.e., the rotor 2, completing the continuous welding of the entire transverse weld. When it is necessary to adjust the axial position of the welding head or make angle adjustments, the second slider 503 remains locked in the current position, providing a stable radial reference for the welding head. One end of the transverse rail 501 is connected to the free end of the vertical rail 901, so that the entire transverse welding mechanism is suspended at the top of the vertical rail 901, forming a compact structure arranged vertically with the vertical welding mechanism.

[0043] Similarly, the linear motion mechanism composed of the second lead screw 502 and the second slider 503 is a classic transmission method that converts rotational motion into linear motion. The second lead screw 502, as the driving member, is driven to rotate by the second drive motor 504, while the second slider 503, as the driven member, converts the rotational torque of the lead screw into a linear thrust along the horizontal rail 501 through a threaded connection. The horizontal rail 501 provides precise guidance for the second slider 503, restricting the slider to move only radially and preventing it from rotating with the lead screw, ensuring the uniqueness of the movement direction and the straightness of the trajectory. The lead of the lead screw determines the distance the slider moves per revolution of the motor. This fixed transmission ratio allows the control unit 13 to accurately calculate the displacement of the slider by controlling the number of revolutions and the rotation angle of the motor, achieving precise position control. Simultaneously, the lead screw thread pair has a certain self-locking characteristic, ensuring that the slider remains stable in its current position without shifting after the motor stops rotating, providing a stable radial reference for subsequent vertical adjustment and welding operations.

[0044] Preferably, in this embodiment, a rotating seat 14 is provided between the vertical rail 901 and the base 1. The rotating seat 14 is rotatably mounted on the base 1, and the vertical rail 901 is connected to the rotating seat 14 and can rotate with the rotating seat 14. The rotating seat 14 is provided with a locking mechanism 15 for locking the rotating seat 14 to the base 1. The base 1 is connected to a driving mechanism 16, which is prior art and is mainly used to drive the rotating seat 14 to rotate. The rotating seat 14 is mainly used to drive the vertical rail 901 to rotate, thereby driving the horizontal rail 501 to rotate. In this way, the horizontal rail 501 and other components can be removed from the end face area of ​​the rotor 2, making it convenient for the rotor 2 to be installed on the base 1. It is worth noting that after the rotor 2 is rotatably installed on the base 1, the base 1 can be rotated in the opposite direction, so that the corresponding vertical rail 901 and horizontal rail 501 can be accurately returned to their initial positions, so that the control unit 13 can obtain the relevant position information. The locking mechanism 15 in this embodiment is existing technology and will not be described further here. For example, the locking mechanism 15 can be integrated into the third drive motor 3 to form a self-locking motor, or a contact locking mechanism 15 can be used.

[0045] In some embodiments of the present invention, the rotor 2 drive assembly includes a third drive motor 3, which is connected to the rotor 2 of the air preheater and is used to drive the rotor 2 to rotate. By directly driving the air preheater rotor 2 to rotate using the third drive motor 3, automated control of the rotor 2's rotation during welding is achieved, replacing the traditional manual turning or assisted hoisting rotation methods, significantly reducing the labor intensity of operators and improving work efficiency. In this embodiment, the third drive motor 3 is a self-locking motor; therefore, after stopping the rotation of the rotor 2, it automatically locks the rotor 2, preventing it from continuing to rotate.

[0046] In this embodiment, the positioning component includes a vertical position sensor 401 and a horizontal position sensor 402. The vertical position sensor 401 is used to monitor the vertical position information of the weld, and the horizontal position sensor 402 is used to monitor the horizontal position information of the weld. Both the vertical position sensor 401 and the horizontal position sensor 402 are connected to the control unit 13.

[0047] Specifically, the aforementioned lateral position sensor 402 monitors the real-time position coordinates of each lateral weld (radial sealing weld) on the end face of rotor 2 in the lateral direction (i.e., the radial direction of rotor 2), while the vertical position sensor 401 monitors the real-time position coordinates of each vertical weld (axial sealing weld) on the side of rotor 2 in the vertical direction (i.e., the axial direction of rotor 2). Both sensors transmit their acquired position information to the control unit 13 in real time. During the rotor 2 stepping positioning stage, the control unit 13 continuously compares the lateral position information of the lateral welds fed back by the lateral position sensor 402 with the pre-stored lateral position information of the lateral welding mechanism. When the two match, the control unit 13 determines that the lateral weld has accurately reached the position of the lateral welding mechanism in the lateral direction, and then issues a command to stop the rotor 2 from rotating and to self-lock.

[0048] After the rotor 2 stops, during the fine alignment stage, the vertical position sensor 401 monitors the real-time vertical (axial) position of the transverse weld and feeds it back to the control unit 13. The control unit 13 drives the transverse welding mechanism to move vertically and compares the real-time vertical position information with the pre-stored vertical position information of the transverse welding mechanism. When the two match, the vertical movement stops, and the transverse welding mechanism and the transverse weld are fully aligned.

[0049] At the same time, the lateral position sensor 402 monitors the real-time lateral (radial) position of the vertical weld at the same angle as the lateral weld and feeds it back to the control unit 13. The control unit 13 drives the vertical welding mechanism to move laterally and compares the real-time lateral position information with the pre-stored lateral position information of the vertical welding mechanism. When the two match, the lateral movement stops, and the vertical welding mechanism and the vertical weld are fully aligned.

[0050] During the welding process, the vertical position sensor 401 and the horizontal position sensor 402 work continuously to monitor whether there is any deviation in the weld position in real time. The control unit 13 dynamically adjusts the motion trajectory of the welding mechanism based on the feedback information to ensure that the welding head always accurately tracks the weld. After the current weld is completed, the rotor 2 continues to rotate to the next angular position, and the positioning component repeats the above monitoring, comparison and positioning cycle until all welds are completed.

[0051] It should be noted that the aforementioned vertical position sensor 401 and horizontal position sensor 402 are both existing technologies. The positioning component is the sensing layer of the entire device, and its core function is to convert the physical quantity of the weld's spatial position into an electrical signal that the control unit 13 can recognize. The vertical position sensor 401 and horizontal position sensor 402 correspond to two orthogonal coordinate axes (vertical corresponds to the rotor 2 axial direction, and horizontal corresponds to the rotor 2 radial direction). The two work together to form a two-dimensional position detection system, which can comprehensively capture the precise position coordinates of the weld in space. The two sensors typically use non-contact detection elements such as laser displacement sensors, vision sensors, or photoelectric sensors. By emitting a detection beam and receiving the reflected signal, the precise distance of the weld relative to the sensor reference point is calculated using triangulation or time-of-flight methods, thereby obtaining the spatial position information of the weld. The sensors transmit the detected position information to the control unit 13 in real time in the form of analog or digital signals. After sampling, filtering, and parsing the signal, the control unit 13 compares and calculates it with the pre-stored fixed position information of each welding mechanism, and generates corresponding motion control commands based on the deviation value to drive each actuator to make precise displacement adjustments. Throughout the process, the sensor operates continuously at an extremely high sampling frequency (typically up to several kilohertz) to ensure that the control unit 13 can acquire real-time dynamic changes in the weld position, thereby achieving high-speed closed-loop control of detection, comparison, execution, and re-detection.

[0052] In this embodiment, the first lateral moving part 10 and the second vertical moving part 6 are existing technologies and can be a telescopic cylinder or a linear slide module, etc. This embodiment specifically uses a telescopic cylinder.

[0053] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A welding equipment for processing air preheater sealing components, characterized in that, include: Base; Rotor drive assembly for driving the rotor of the air preheater to rotate; A positioning component for monitoring the welding position on the rotor; The welding assembly includes a transverse welding mechanism and a vertical welding mechanism. The transverse welding mechanism is used to weld a sealing assembly located on the rotor end face along the radial direction of the rotor, and the vertical welding mechanism is used to weld a sealing assembly located on the rotor side along the axial direction of the rotor. The control unit is connected to the positioning component, the horizontal welding mechanism, and the vertical welding mechanism.

2. The welding equipment for processing air preheater sealing components according to claim 1, characterized in that, The vertical welding mechanism includes a first vertical moving part, at least one first horizontal moving part, and at least one first welding head. The first vertical moving part is disposed on the base, and the moving end of the first vertical moving part moves along the axial direction of the rotor. The first horizontal moving parts are all disposed at the moving ends of the first vertical moving parts, and the moving ends of the first horizontal moving parts all move in a direction perpendicular to the axis of the rotor. The first welding heads are correspondingly disposed on the moving ends of the first horizontal moving parts. A first rotating part is disposed between each first welding head and the moving end of the corresponding first horizontal moving part for adjusting the angle of the first welding head.

3. The welding equipment for processing air preheater sealing components according to claim 2, characterized in that, The first vertical moving part includes a vertical rail, a first lead screw, and a first slider. The vertical rail is disposed on the base, and the extension direction of the vertical rail is parallel to the axial direction of the rotor. The first slider is slidably disposed on the vertical rail along the extension direction of the vertical rail. The first lead screw is rotatably disposed on the vertical rail and is parallel to the extension direction of the vertical rail. The first lead screw passes through the first slider and is threadedly engaged with the first slider. The first slider is the moving end of the first vertical moving part. One end of the first lead screw is connected to a first drive motor for driving its rotation. The first drive motor is connected to the control unit.

4. The welding equipment for processing the air preheater sealing assembly according to claim 3, characterized in that, The transverse welding mechanism includes a second transverse moving part, at least one second vertical moving part, and at least one second welding head. The second transverse moving part is disposed at the free end of the vertical rail, and the moving end of the second transverse moving part moves radially along the rotor. The second vertical moving part is disposed at the moving end of the second transverse moving part, and the moving end of the second vertical moving part moves in a direction parallel to the axis of the rotor. The second welding heads are correspondingly disposed on the moving ends of the second vertical moving parts. A second rotating part is disposed between each second welding head and the corresponding moving end of the second vertical moving part for adjusting the angle of the second welding head.

5. The welding equipment for processing the air preheater sealing assembly according to claim 4, characterized in that, The second lateral moving part includes a horizontal rail, a second lead screw, and a second slider. The horizontal rail is arranged radially along the rotor, and one end of the horizontal rail is connected to the free end of the vertical rail. The second slider is slidably disposed on the horizontal rail along its extension direction. The second lead screw is rotatably disposed on the horizontal rail and parallel to its extension direction. The second lead screw passes through the second slider and is threadedly engaged with the second slider. The second slider is the moving end of the second lateral moving part. One end of the second lead screw is connected to a second drive motor for driving its rotation. The second drive motor is connected to the control unit.

6. The welding equipment for processing air preheater sealing components according to claim 5, characterized in that, A rotating seat is provided between the vertical rail and the base. The rotating seat is rotatably mounted on the base. The vertical rail is connected to the rotating seat and can rotate with the rotating seat. The rotating seat is provided with a locking mechanism for locking the rotating seat to the base.

7. The welding equipment for processing air preheater sealing components according to claim 1, characterized in that, The rotor drive assembly includes a third drive motor, which is connected to the rotor of the air preheater and is used to drive the rotor to rotate.

8. The welding equipment for processing air preheater sealing components according to claim 1, characterized in that, The positioning component includes a vertical position sensor and a horizontal position sensor. The vertical position sensor is used to monitor the vertical position information of the weld, and the horizontal position sensor is used to monitor the horizontal position information of the weld. Both the vertical position sensor and the horizontal position sensor are connected to the control unit.

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