Welding device and method for split tee assembly

Abstract

This invention belongs to the field of welding technology for split tees, and discloses a welding device and method for split tees. Specifically, the welding device for split tees includes a support component, a protective component connected to one end of the support component, a load-bearing component between the support component and the protective component, and a feed groove and a docking groove connected to the end face of the load-bearing component, with the feed groove and the docking groove located on different end faces of the load-bearing component. A limiting component is connected to both the feed groove and the docking groove. The limiting component, the load-bearing component, and the intelligent control module work together to achieve precise positioning and efficient pre-processing of the welded parts. The limiting sleeve is driven by a telescopic rod and, combined with the limiting block of the connecting part, abuts and fixes the inner wall of the welded parts. A pressure sensor provides real-time pressure feedback, and the intelligent control module dynamically adjusts the pressure, ensuring both stable fixation and preventing deformation of the welded parts.

Description

Technical Field

[0001] This invention belongs to the field of welding technology for split tee joints, specifically a device and method for welding split tee joints. Background Technology

[0002] In the field of welding technology for split tees, traditional welding operations face many pain points, mainly reflected in the following aspects: insufficient positioning accuracy of welded parts, difficulty in accurately connecting split tees of different diameters and angles, and the easy presence of impurities and oxide layers in the area to be welded, which directly affects the welding quality; the welding process relies on manual control, resulting in low weld seam tracking accuracy and easy weld seam defects due to factors such as vibration and abnormal temperature.

[0003] Patent application number CN202010801190.2 discloses a method for welding a split tee joint, including the following steps: fitting an upper and lower protective plate onto the outside of the main pipe to form two straight welds and two circumferential welds; the intersections of the two circumferential welds with each straight weld form intersection points A and B, respectively; processing the straight welds and circumferential welds; dividing the two straight welds into multiple segments and welding them simultaneously; after the two straight welds are welded, welding the two circumferential welds; dividing each circumferential weld into two segments, including segment A containing intersection point A and segment B containing intersection point B, wherein segment B is welded clockwise and segment A is welded counterclockwise, and segments A and B are welded simultaneously. This method utilizes different welding procedures for the straight and circumferential welds to avoid stress concentration and hydrogen cracking accidents; the welding bevel of the straight welds adopts a single-sided bevel type, significantly reducing the amount of welding work.

[0004] Meanwhile, the harmful fumes generated during welding are directly released, endangering the health of operators; the operation process lacks intelligent management and control, welding parameter adjustment is lagging behind, quality inspection efficiency is low, and historical data is difficult to trace, which cannot meet the needs of large-scale, high-precision welding.

[0005] To address the aforementioned technical problems, this invention proposes a welding device and method for butt welding of split tee joints. Summary of the Invention

[0006] The purpose of this invention is to address the above-mentioned problems. This invention provides a welding device and method for butt welding of tee joints, which has the advantages of high automation level and high operational safety in welding operations.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a butt welding device for a split tee joint, comprising a support assembly, a protective assembly connected to one end of the support assembly, a load-bearing assembly provided between the support assembly and the protective assembly, a feed groove and a butt groove respectively connected to the end face of the load-bearing assembly, and the feed groove and the butt groove being located on different end faces of the load-bearing assembly, and a limiting assembly connected to both the feed groove and the butt groove; The limiting component includes a limiting sleeve with a limiting cavity extending through it. A connecting part is slidably provided in the limiting cavity. A grinding block is rotatably provided on the side of the connecting part near the bearing component. The grinding block is rotatably connected in the limiting cavity. A telescopic rod is connected to the outer periphery of the limiting sleeve.

[0008] Preferably, the support assembly includes a support plate, one end of which is connected to a plurality of connecting brackets, the protective assembly is connected to the end of the connecting brackets away from the support plate, and the load-bearing assembly is connected to the support plate.

[0009] Preferably, the supporting component includes a supporting block, a working cavity is formed in the supporting block, a working component is connected in the working cavity, and the feeding groove and the docking groove are both in communication with the working cavity.

[0010] Preferably, the working component includes a workbench, one end of which is connected to an air guide column, the end of which is away from the workbench is connected to the support block, an air intake hole is formed through the workbench, an air guide cavity is formed through the air guide column, and the air intake hole communicates with the air guide cavity.

[0011] Preferably, the connecting part includes a connecting plate, which is slidably connected to the cavity wall of the limiting cavity. A movable column is connected to one end of the connecting plate near the grinding block, and a connecting block is connected to the other end of the movable column away from the connecting plate. Multiple limiting blocks are movably arranged on the outer circumference of the connecting block.

[0012] Preferably, the protective component includes a cover plate, and a visual inspection unit for detecting the welding position and a vibration sensor are respectively connected to one end of the cover plate near the support component.

[0013] Preferably, a welding part is connected to one end of the cover plate near the bearing component, and a driving component is connected to one end of the welding part.

[0014] Preferably, an air purification component is connected inside the air guide cavity.

[0015] The method using a split tee welding device includes the following steps: S1. Place the parts to be welded into the corresponding feed trough and docking trough respectively, control the start of the limiting component, the telescopic rod drives the limiting sleeve to move to the position corresponding to the end of the part to be welded, the limiting block unfolds and abuts against the inner wall of the part to fix the part to be welded, and then control the telescopic rod to push the limiting sleeve to move, and transport the part to the worktable above the working chamber, and accurately dock it to the welding station. S2. The connecting plate slides to the preset position in the limiting cavity, so that the grinding block contacts the area to be welded of the welding part. At the same time, the movable column is controlled to drive the grinding block to rotate, and the speed of the grinding block and the feed of the connecting plate are adjusted to grind and clean the area to be welded of the welding part, removing surface impurities and oxide layers. S3. The control drive component is started, driving the welding part to move to the welding start position, and at the same time controlling the welding part to start welding according to the preset welding current, voltage and speed; during the welding process, the vision inspection unit collects and transmits weld seam images in real time, analyzes the weld seam trajectory and welding quality through image recognition algorithm, adjusts the operating parameters of the drive component, and realizes automatic weld seam tracking welding. S4. When welding begins, start the fan in the air intake and adjust it to the preset high speed. The welding fumes enter the air guide chamber through the air intake. S5. During and after welding, the visual inspection department continuously collects weld images. The intelligent control module analyzes parameters such as the width, height, and flatness of the weld to determine whether the weld is qualified. The vibration sensor detects the vibration signal of the weld after welding to help determine the welding strength. S6. After welding and inspection are completed, the limiting block retracts, the telescopic rod drives the limiting sleeve to reset, and at the same time the worktable is slightly raised, making it convenient for operators or automated equipment to take out the welded split tee.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The limiting component, load-bearing component, and intelligent control module work together to achieve precise positioning and efficient pre-processing of the welded parts. The limiting sleeve is driven by a telescopic rod and, together with the limiting block of the connecting part, abuts and fixes the inner wall of the welded parts. The pressure sensor provides real-time pressure feedback, and the intelligent control module dynamically adjusts the pressure to ensure both stability and prevent deformation of the welded parts. At the same time, during the conveying of the welded parts, the connecting plate drives the grinding block to precisely fit the area to be welded. The movable column drives the grinding block to rotate, and the torque sensor and displacement sensor work together to adjust the grinding parameters, efficiently removing surface impurities and oxide layers, providing a clean and flat contact surface for welding, and ensuring welding quality from the source.

[0017] 2. By linking the protective components, drive components, welding section and intelligent control module, the welding process is automated and precisely controlled. The drive components control the movement trajectory, speed and angle of the welding section according to preset parameters. The vision inspection section collects weld images in real time and analyzes weld parameters through image recognition algorithms. The intelligent control module dynamically adjusts welding current, voltage and other parameters to achieve automatic weld tracking. At the same time, the vibration sensor monitors the device vibration in real time and promptly alarms or adjusts parameters when abnormalities occur to avoid weld defects caused by vibration and overheating. This ensures that the weld width, height, flatness and other indicators meet the standards and improves welding stability and reliability. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the overall device of the present invention; Figure 2 This is a schematic diagram of the connection structure of the working components of the present invention; Figure 3 This is a cross-sectional structural diagram of the overall device of the present invention; Figure 4 This is a three-dimensional structural diagram of the working components of the present invention; Figure 5 This is a cross-sectional structural diagram of the working component of the present invention; Figure 6 This is a three-dimensional structural diagram of the limiting component of the present invention; Figure 7 This is a cross-sectional structural diagram of the limiting component of the present invention; Figure 8 This is a three-dimensional structural diagram of the protective component of the present invention.

[0019] Figure Descriptions: 1. Support Component; 101. Support Plate; 102. Connecting Frame; 2. Protective Component; 201. Cover Plate; 202. Vision Inspection Unit; 203. Vibration Sensor; 3. Feed Chute; 4. Docking Chute; 5. Restriction Component; 501. Restriction Sleeve; 502. Connecting Part; 5021. Connecting Plate; 5022. Movable Column; 5023. Connecting Block; 5024. Restriction Block; 503. Restriction Cavity; 504. Grinding Block; 505. Telescopic Rod; 6. Drive Component; 7. Bearing Component; 701. Bearing Block; 702. Working Cavity; 8. Working Component; 801. Worktable; 802. Suction Hole; 803. Air Guide Column; 804. Air Guide Cavity; 9. Welding Part. Detailed Implementation

[0020] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] like Figures 1-8 As shown, the welding device for split tee joints includes a support component 1 for supporting and protecting the components. One end of the support component 1 is connected to a protective component 2 to prevent slag spatter during welding. Between the support component 1 and the protective component 2, a bearing component 7 is provided to support the position of the welded parts. The end face of the bearing component 7 is respectively connected to a feed chute 3 for the main pipe to enter and exit and a docking groove 4 for the movement of the welded pipe. In this scheme, there are two feed chute 3s and two docking grooves 4. The two feed chute 3s are located on two opposite end faces of the bearing component 7, and the two docking grooves 4 are located on the other two end faces of the bearing component 7. At the same time, the connection angles between the two docking grooves 4 and the bearing component 7 are different to meet the welding requirements of split tee pipes with different angles. The feed chute 3 and the docking groove 4 are located on different end faces of the bearing component 7 to meet the conveying and welding requirements of the tee pipe. The feed chute 3 and the docking groove 4 are each connected to a limiting component 5 for the position constraint and movement of the pipe.

[0022] The device also includes an intelligent control module, which is electrically connected to the limiting component 5, the protective component 2, the working component 8, the driving component 6, and the welding section 9. It is used to receive signals from each component and output control commands to achieve automated and precise control of the entire welding process. The intelligent control module has a built-in PLC controller and a human-machine interface. The human-machine interface can display the device's operating status, welding parameters, and test results in real time. Operators can input welding process parameters and set the welding process through this interface, and it also supports parameter storage and related operating data query.

[0023] Meanwhile, both the feeding trough 3 and the docking trough 4 are equipped with weight sensors for detecting the quality of the welded parts, and the weight sensors are electrically connected to the intelligent control module. When the detected weight exceeds the maximum load-bearing threshold of the feeding trough 3 and the docking trough 4, the intelligent control module issues an alarm signal and controls the limiting component 5 to stop operating, preventing damage to the device or a decrease in welding accuracy due to overload.

[0024] In use, the area of ​​the bearing component 7 is protected by the support component 1 and the protective component 2. The operator inputs the welding-related parameters and sets the welding process through the intelligent control module. Then, according to the welding requirements, the pipe to be welded is placed in the corresponding feed trough 3 and docking trough 4. The intelligent control module controls the start of the limiting component 5. The limiting component 5 moves to transport the material to be welded to the bearing component 7, which facilitates subsequent welding.

[0025] To ensure stable movement of the workpiece to be welded and reduce the interference of impurities on the workpiece on the welding effect, the limiting component 5 includes a limiting sleeve 501 for spatial constraint. A limiting cavity 503 is provided through the limiting sleeve 501, wherein the diameter of the limiting cavity 503 is always larger than the diameter of the workpiece to be welded, thereby ensuring that the workpiece can move within the limiting cavity 503. A connecting part 502 for fixing the position of the workpiece is slidably provided within the limiting cavity 503. A polishing block 504 for polishing the outer periphery of the workpiece is rotatably provided on the side of the connecting part 502 near the bearing component 7. The polishing block 504 is rotatably connected within the limiting cavity 503. When the workpiece moves, the workpiece and the polishing block 504 rotate relative to each other, causing the polishing block 504 to remove impurities from the outer periphery of the workpiece. A telescopic rod 505 for controlling the height of the limiting sleeve 501 is connected to the outer periphery of the limiting sleeve 501, and the telescopic rod 505 slides synchronously with the limiting sleeve 501 in the feed groove 3 and the docking groove 4.

[0026] The connecting plate 5021 is equipped with a displacement sensor for detecting the sliding displacement of the connecting plate 5021 within the limiting cavity 503. The movable column 5022 is equipped with a torque sensor for detecting the rotational torque of the movable column 5022. When the torque exceeds the preset range, the intelligent control module determines that the grinding block 504 is in too tight contact with the weldment or that there are hard impurities on the surface of the weldment. It immediately adjusts the rotational speed of the movable column 5022 or controls the connecting plate 5021 to retract to avoid damage to the grinding block 504 or scratches on the surface of the weldment. The limiting block 5024 is equipped with a pressure sensor for detecting the contact pressure of the limiting block 5024 against the inner wall of the weldment. All of the above sensors are electrically connected to the intelligent control module. At the same time, the intelligent control module accurately controls the moving position of the connecting plate 5021 according to the displacement signal to ensure that the grinding block 504 makes precise contact with the area to be welded of the weldment. It also automatically adjusts the distance between the limiting block 5024 and the connecting block 5023 according to the pressure signal to ensure that the pressure is maintained within the preset range, thus ensuring the stability of the weldment and avoiding deformation of the weldment due to excessive pressure.

[0027] Furthermore, the support assembly 1 includes a support plate 101 for ensuring stable installation of the device. One end of the support plate 101 is connected to a plurality of connecting frames 102 for maintaining the height of the processing space. The protective assembly 2 is connected to the end of the connecting frame 102 away from the support plate 101. The load-bearing assembly 7 is connected to the support plate 101. In this way, on the one hand, the stability of the device is maintained when welding the workpiece, and on the other hand, the connecting frame 102 ensures that the protective assembly 2 will not come into contact with the workpiece, while satisfying the protective function of the protective assembly 2 for the welding area.

[0028] Furthermore, the support component 7 includes a support block 701 for connecting and supporting the feed trough 3 and the docking groove 4. The support block 701 has a working cavity 702 for welding the welded parts. The working cavity 702 is connected to a working component 8 for supporting the welding area of ​​the welded parts. At the same time, the working component 8 absorbs the gas generated during the welding process to prevent the welding gas from overflowing and affecting the health of the user. Both the feed trough 3 and the docking groove 4 are connected to the working cavity 702 to ensure that the welded parts in the feed trough 3 and the docking groove 4 can be moved to the working component 8 in the working cavity 702 to meet subsequent welding needs.

[0029] To improve real-time monitoring of the movement position of the welded parts, a position sensor is installed on the bearing block 701 to monitor the position of the welded parts in the working cavity 702. The position signal of the welded parts is fed back to the intelligent control module, which then accurately adjusts the movement distance and movement speed of the limiting component 5 according to the position signal, ensuring that the welded parts are accurately aligned with the welding station.

[0030] Furthermore, to ensure that no harmful fumes are emitted during the welding process, and to prevent the welding condition from being affected by support issues, the working assembly 8 includes a worktable 801 for supporting the welding area of ​​the workpiece. One end of the worktable 801 is connected to a guide column 803 for supporting the height of the worktable 801. The end of the guide column 803 away from the worktable 801 is connected to a support block 701, thereby ensuring the connection stability of the guide column 803 and the stability of the plane of the worktable 801. The worktable 801 has a through-hole 802 for absorbing welding fumes, and the air guide column 803 has a through-hole 804 for conducting fumes. The through-hole 802 is connected to the air guide chamber 804. In this way, during the welding process, the welding fumes are absorbed by the through-hole 802, which then guides the fumes through the through-hole 802 into the air guide chamber 804 for purification and discharge. This avoids the welding fumes being directly discharged between the support component 1 and the protective component 2, reducing the harm of fumes to the user.

[0031] It should be noted that the air intake 802 is equipped with a fan for drawing in air, ensuring that the fumes generated during welding can fully enter the air guide chamber 804.

[0032] The fan inside the air intake 802 is electrically connected to the intelligent control module. The intelligent control module automatically adjusts the fan speed according to the working status of the welding section 9. That is, when welding starts, the fan automatically starts and adjusts to the preset high speed to ensure that the welding fumes are absorbed quickly and efficiently. When welding is paused or ended, the fan automatically adjusts to the low speed and runs for a preset time before turning off, which ensures both smoke exhaust effect and energy saving.

[0033] Meanwhile, a gas concentration sensor is installed in the air guide chamber 804. The gas concentration sensor is electrically connected to the intelligent control module to detect the concentration of pollutants in the purified gas in real time. When the concentration exceeds the preset standard, the intelligent control module issues an alarm signal to remind the operator to handle it in time. The air purification component in the air guide chamber 804 is equipped with a filter status sensor. The filter status sensor is electrically connected to the intelligent control module to detect the degree of filter blockage and purification efficiency in real time. When the filter needs to be replaced or the purification efficiency drops to the preset value, the intelligent control module issues a reminder signal through the human-machine interface to facilitate timely maintenance by the operator.

[0034] Furthermore, to ensure that any area on the surface of the weldment can be ground to meet the welding requirements, the connecting part 502 includes a connecting plate 5021 for supporting the connection. The connecting plate 5021 is slidably connected to the cavity wall of the limiting cavity 503, meaning that the connecting plate 5021 can reciprocate along the cavity of the limiting cavity 503, thereby changing the position of the connecting plate 5021 within the limiting cavity 503, and thus adjusting the contact position between the weldment and the grinding block 504. A rotatable movable column 5022 is connected to one end of the connecting plate 5021 near the grinding block 504, and a connecting block 5023 is connected to the other end of the movable column 5022 away from the connecting plate 5021. Multiple limiting blocks 5024 are movably provided on the outer circumference of 023 to abut and fix the inner sidewall of the welded part. The distance between the limiting block 5024 and the connecting block 5023 is adjustable to ensure that the limiting block 5024 can abut the inner wall of the welded part with different diameters, thereby ensuring the connection stability between the welded part and the connecting part 502. Then, during the welding process, the distance between the welded part and the worktable 801 is changed by the telescopic rod 505. The connecting block 5023 is rotated by the movable column 5022, thereby causing the welded part to rotate and changing the welding area between the welding part 9 and the welded part. Then, the telescopic rod 505 is controlled to reset to meet the normal welding contact between the welding part 9 and the welded part.

[0035] In use, the parts to be welded are placed into the feed trough 3 and the corresponding angled docking groove 4. The intelligent control module controls the telescopic rod 505 to drive the limiting sleeve 501 to move to the position corresponding to the end of the part to be welded. The limiting block 5024 of the connecting part 502 unfolds and abuts against the inner wall of the part to be welded. Through the feedback signal from the pressure sensor on the limiting block 5024, the intelligent control module adjusts the abutting pressure of the limiting block 5024 to a preset value to complete the fixing of the part to be welded. Then, according to the position sensor signal on the bearing block 701, the intelligent control module controls the telescopic rod 505 to push the limiting sleeve 501 to move, conveying the main pipe and branch pipe required for welding to the worktable 801 above, and accurately docking them to the welding worker. Simultaneously, as the welded part moves with the limiting sleeve 501, the intelligent control module controls the connecting plate 5021 to slide to the preset position within the limiting cavity 503 according to the input welded part specifications and preset grinding process, so that the grinding block 504 contacts the area to be welded of the welded part. At the same time, the intelligent control module controls the movable column 5022 to drive the grinding block 504 to rotate. The grinding torque is monitored in real time by the torque sensor. The intelligent control module dynamically adjusts the rotation speed of the grinding block 504 and the feed amount of the connecting plate 5021 according to the torque signal to automatically grind and clean the area to be welded of the welded part, removing surface impurities and oxide layers. After grinding is completed, the intelligent control module controls the grinding block 504 to stop rotating and the connecting plate 5021 to reset.

[0036] Simultaneously, as the welded part moves with the limiting sleeve 501, the connecting plate 5021 slides within the limiting cavity 503 according to the area to be welded. This causes the limiting block 5024 and the welded part to change their positions within the limiting cavity 503, thereby altering the contact position between the welded part and the grinding block 504. When the grinding block 504 approaches the area to be welded, it is controlled to rotate, allowing the grinding block 504 to clean the surface of the welded part and ensure normal welding.

[0037] Furthermore, in order to avoid slag spatter during the welding process and to effectively detect the welding quality, the protective component 2 includes a cover plate 201 for protecting the slag. The end of the cover plate 201 near the support component 1 is connected to a vision inspection unit 202 for detecting the welding position and a vibration sensor 203, thereby using the vision inspection unit 202 and the vibration sensor 203 to detect and identify the weld, ensuring the stable connection state of the weld.

[0038] The visual inspection unit 202 uses a high-definition industrial camera and image recognition algorithm to collect image information of the welding area in real time and transmit it to the intelligent control module. The intelligent control module analyzes and processes the image, identifies parameters such as the width, height, and flatness of the weld, and compares them with preset standard parameters. If there is a deviation, it automatically adjusts the welding current, voltage, and welding speed of the welding unit 9. The vibration sensor 203 detects the vibration frequency and amplitude in real time during the welding process. When the vibration data exceeds the preset range, the intelligent control module judges that the welding process is unstable, immediately issues an alarm signal, and adjusts the welding parameters or suspends welding to prevent weld defects caused by vibration.

[0039] Furthermore, the end of the cover plate 201 near the bearing component 7 is connected to a welding part 9 for fixing the welded joint area. One end of the welding part 9 is connected to a drive component 6 for controlling the working state of the welding part 9. The drive component 6 is used to control the movement trajectory, welding speed and welding angle of the welding part 9 to realize automated tracking welding of the weld.

[0040] Furthermore, an air purification component for treating harmful fumes is connected inside the air guide cavity 804.

[0041] After the device is started, the main pipe and branch pipe to be welded are placed in the corresponding feed trough 3 and docking trough 4 respectively. The weight sensors in the feed trough 3 and docking trough 4 detect the weight of the welded parts in real time. If the weight exceeds the maximum load threshold, the intelligent control module immediately issues an alarm signal and prohibits the start of the limiting component 5 to avoid overload causing damage to the device or affecting the welding accuracy.

[0042] Once the weight detection is successful, the intelligent control module sends a start command to the limiting component 5. The telescopic rod 505 drives the limiting sleeve 501 to slide along the feed groove 3 or the docking groove 4 until it moves to the position corresponding to the end of the welded part. At this time, the limiting block 5024 of the connecting part 502 unfolds under the control of the intelligent control module and abuts against the inner wall of the welded part. The pressure sensor on the limiting block 5024 collects the abutment pressure signal in real time and feeds it back to the intelligent control module. The intelligent control module dynamically adjusts the distance between the limiting block 5024 and the connecting block 5023 according to the preset pressure range to ensure that the pressure is maintained within a reasonable range, which ensures the fixation stability of the welded part and the connecting part 502, and avoids the deformation of the welded part due to excessive pressure.

[0043] Meanwhile, the position sensor on the bearing block 701 monitors the position of the welded part in the working chamber 702 in real time. The intelligent control module precisely adjusts the extension and retraction of the telescopic rod 505 according to the position signal, thereby controlling the moving distance and speed of the limiting sleeve 501, smoothly transporting the main pipe and branch pipe to the worktable 801 in the working chamber 702, and accurately docking them to the preset welding station to complete the positioning preparation before welding.

[0044] During the conveying of the welded parts, the intelligent control module simultaneously initiates the grinding pretreatment program. Based on the input welded parts specifications and preset grinding process, the intelligent control module sends a command to the connecting part 502, and the connecting plate 5021 slides along the cavity wall of the limiting cavity 503 to the preset position, so that the grinding block 504 makes precise contact with the area to be welded of the welded parts.

[0045] The displacement sensor on the connecting plate 5021 provides real-time feedback of the sliding displacement signal, ensuring accurate contact between the grinding block 504 and the area to be welded. Subsequently, the movable column 5022 drives the grinding block 504 to rotate, cleaning surface impurities and oxide layers from the area to be welded. The torque sensor inside the movable column 5022 detects the rotational torque in real time. If the torque exceeds the preset range, the intelligent control module determines that the grinding block 504 is in too tight contact with the weldment or that there are hard impurities on the surface of the weldment. It immediately adjusts the rotation speed of the movable column 5022 or controls the connecting plate 5021 to retract, preventing damage to the grinding block 504 or scratches on the surface of the weldment. After grinding is completed, the intelligent control module controls the grinding block 504 to stop rotating, and the connecting plate 5021 resets, providing a clean welding surface for subsequent welding operations.

[0046] After welding preparation is completed, the intelligent control module sends working instructions to the drive assembly 6 and the welding section 9. The drive assembly 6, including components such as servo motors, controls the welding section 9 to move to the welding starting position and starts the welding operation according to the preset welding trajectory, welding speed, and welding angle. During the welding process, the cover plate 201 of the protective assembly 2 serves to block welding slag from splashing, preventing welding slag from damaging surrounding components or affecting the safety of operators.

[0047] Meanwhile, the high-definition industrial camera of the vision inspection unit 202 collects image information of the welding area in real time. After being transmitted to the intelligent control module, the image recognition algorithm analyzes parameters such as the width, height, and flatness of the weld and compares them with preset standard parameters. If there is a deviation, the intelligent control module immediately adjusts the welding current, voltage, and welding speed of the welding unit 9 to ensure that the weld quality meets the requirements.

[0048] Vibration sensor 203 detects the vibration frequency and amplitude in real time during the welding process. When the vibration data exceeds the preset range, the intelligent control module determines that the welding process is unstable, immediately issues an alarm signal, and adjusts the welding parameters or suspends welding to prevent weld defects caused by vibration.

[0049] While welding is underway, the intelligent control module activates the fume treatment system. The fan inside the suction port 802 automatically starts and adjusts to a preset high speed at the start of welding, generating negative pressure to draw the harmful fumes generated during welding into the suction port 802. The fumes then enter the air guide chamber 804 of the air guide column 803, where they are filtered and purified by the air purification components to remove harmful pollutants. A gas concentration sensor within the air guide chamber 804 monitors the pollutant concentration in the purified gas in real time. If the concentration exceeds a preset standard, the intelligent control module issues an alarm signal, reminding the operator to check the air purification components promptly.

[0050] The filter status sensor monitors the filter clogging level and purification efficiency of the air purification component in real time. When the filter needs replacement or the purification efficiency drops to a preset value, the intelligent control module sends a reminder signal through the human-machine interface. After welding is paused or completed, the intelligent control module controls the fan to maintain low speed operation for 5-10 seconds to ensure that residual fumes in the working chamber 702 are completely discharged before shutting down the fan, preventing harmful fumes from escaping and protecting the health of operators.

[0051] During and after welding, the quality inspection system operates continuously. The vision inspection unit 202 continuously acquires weld images, the intelligent control module continuously analyzes weld parameters, and the vibration sensor 203 detects the vibration signal of the weld after welding to help determine the welding strength. The inspection results are displayed in real time on the human-machine interface.

[0052] If the test result is satisfactory, the intelligent control module controls the limiting block 5024 of the limiting component 5 to retract, the telescopic rod 505 drives the limiting sleeve 501 to reset, and simultaneously controls the worktable 801 to slightly lift, making it convenient for operators or automated equipment to remove the welded split tee. If the test result is unsatisfactory, the intelligent control module issues an alarm signal to prompt the operator to handle the situation. After all operations are completed, the intelligent control module controls each component to reset to its initial state, automatically storing historical data such as welding parameters and test results for subsequent querying and traceability. The device then awaits the next batch of welding operations.

[0053] The present invention also includes a method using a butt welding device for split tee joints, comprising the following steps: S1. The operator inputs the specifications and welding process parameters of the welded parts through the human-machine interface of the intelligent control module, and sets the welding process. The intelligent control module stores the parameters and generates corresponding control commands. S2. Place the main pipe and branch pipe to be welded into the corresponding feed trough 3 and docking trough 4 respectively. The intelligent control module controls the start of the limiting component 5. The telescopic rod 505 drives the limiting sleeve 501 to move to the position corresponding to the end of the weldment. The limiting block 5024 of the connecting part 502 unfolds and abuts against the inner wall of the weldment. Through the feedback signal from the pressure sensor on the limiting block 5024, the intelligent control module adjusts the abutting pressure of the limiting block 5024 to the preset value to complete the fixing of the weldment. Then, according to the position sensor signal on the bearing block 701, the intelligent control module controls the telescopic rod 505 to push the limiting sleeve 501 to move, and transport the main pipe and branch pipe to the worktable 801 in the working chamber 702, and accurately dock them to the welding station. S3. The intelligent control module controls the connecting plate 5021 to slide to the preset position in the limiting cavity 503 according to the input welding part specifications and preset grinding process, so that the grinding block 504 contacts the area to be welded of the welding part. At the same time, it controls the movable column 5022 to drive the grinding block 504 to rotate. The grinding torque is monitored in real time by the torque sensor, and the rotation speed of the grinding block 504 and the feed amount of the connecting plate 5021 are dynamically adjusted according to the torque signal to automatically grind and clean the area to be welded of the welding part, remove surface impurities and oxide layer. After grinding is completed, the intelligent control module controls the grinding block 504 to stop rotating and the connecting plate 5021 to reset. S4. The control drive component 6 is started, and the servo motor drives the welding part 9 to move to the welding start position. At the same time, the control welding part 9 starts welding according to the preset welding current, voltage and speed. During the welding process, the vision inspection unit 202 collects the weld seam image in real time and transmits it to the intelligent control module. The intelligent control module analyzes the weld seam trajectory and welding quality through image recognition algorithm, and dynamically adjusts the operating parameters of the drive component 6 to realize automatic weld seam tracking welding. At the same time, the vibration sensor 203 detects the vibration status of the device. The intelligent control module adjusts the welding parameters in real time according to the detection signal to ensure the stability of the welding process. S5. When welding begins, the intelligent control module automatically starts the fan in the suction port 802 and adjusts it to a preset high speed. The welding fumes enter the air guide chamber 804 through the suction port 802, are purified by the air purification component, and are then discharged. The gas concentration sensor detects the concentration of pollutants in the purified gas in real time. The intelligent control module judges the purification effect based on the concentration signal. If the concentration exceeds the standard, an alarm is issued. When welding is paused or completed, the fan is controlled to maintain a low speed for 5-10 seconds to ensure that the residual fumes are completely discharged before the fan is turned off. S6. During and after welding, the visual inspection unit 202 continuously collects weld images. The intelligent control module analyzes parameters such as the width, height, and flatness of the weld and compares them with preset standard parameters to determine whether the weld is qualified. The vibration sensor 203 detects the vibration signal of the weld after welding to help determine the welding strength. The inspection results are displayed in real time on the human-machine interface. Qualified products automatically enter the next process, while unqualified products issue an alarm signal to prompt the operator to handle the issue. S7. After welding and inspection are completed, the intelligent control module controls the limiting block 5024 of the limiting component 5 to retract, the telescopic rod 505 drives the limiting sleeve 501 to reset, and at the same time controls the worktable 801 to lift slightly, so that the operator or automated equipment can take out the welded split tee. Then the intelligent control module controls each component to reset to the initial state, waiting for the next batch of welding operations. At the same time, it automatically stores the parameters, inspection results and other historical data of this welding, which is convenient for subsequent query and traceability.

[0054] It should be noted that, in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0055] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A butt welding device for a split tee joint, comprising a support assembly (1), characterized in that: A protective component (2) is connected to one end of the support component (1). A bearing component (7) is provided between the support component (1) and the protective component (2). A feed groove (3) and a docking groove (4) are respectively connected to the end face of the bearing component (7). The feed groove (3) and the docking groove (4) are located on different end faces of the bearing component (7). A limiting component (5) is connected in both the feed groove (3) and the docking groove (4). The limiting component (5) includes a limiting sleeve (501), a limiting cavity (503) is provided through the limiting sleeve (501), a connecting part (502) is slidably provided in the limiting cavity (503), a grinding block (504) is rotatably provided on the side of the connecting part (502) near the bearing component (7), the grinding block (504) is rotatably connected in the limiting cavity (503), and a telescopic rod (505) is connected to the outer periphery of the limiting sleeve (501).

2. The butt welding device for split tee joints according to claim 1, characterized in that: The support component (1) includes a support plate (101), and a plurality of connecting frames (102) are connected to one end of the support plate (101). The protective component (2) is connected to the end of the connecting frame (102) away from the support plate (101), and the load-bearing component (7) is connected to the support plate (101).

3. The butt welding device for split tee joints according to claim 2, characterized in that: The bearing component (7) includes a bearing block (701), a working cavity (702) is provided in the bearing block (701), a working component (8) is connected in the working cavity (702), and the feed groove (3) and the docking groove (4) are both connected to the working cavity (702).

4. The butt welding device for split tee joints according to claim 3, characterized in that: The working component (8) includes a workbench (801), one end of which is connected to an air guide column (803). The end of the air guide column (803) away from the workbench (801) is connected to the support block (701). An air intake hole (802) is provided through the workbench (801), and an air guide cavity (804) is provided through the air guide column (803). The air intake hole (802) communicates with the air guide cavity (804).

5. The butt welding device for split tee joints according to claim 1, characterized in that: The connecting part (502) includes a connecting plate (5021), which is slidably connected to the cavity wall of the limiting cavity (503). A movable column (5022) is connected to one end of the connecting plate (5021) near the grinding block (504), and a connecting block (5023) is connected to one end of the movable column (5022) away from the connecting plate (5021). Multiple limiting blocks (5024) are movably arranged on the outer circumference of the connecting block (5023).

6. The butt welding device for split tee joints according to claim 1, characterized in that: The protective component (2) includes a cover plate (201), and a visual inspection unit (202) for detecting the welding position and a vibration sensor (203) are respectively connected to one end of the cover plate (201) near the support component (1).

7. The butt welding device for split tee joints according to claim 6, characterized in that: The cover plate (201) is connected to a welding part (9) at one end near the bearing component (7), and a driving component (6) is connected to one end of the welding part (9).

8. The butt welding device for split tee joints according to claim 4, characterized in that: An air purification component is connected inside the air guide cavity (804).

9. The method implemented using the butt welding device for split tees as described in any one of claims 1-8, characterized in that: Includes the following steps: S1. Place the parts to be welded into the corresponding feed trough (3) and docking trough (4), start the control limiting component (5), and drive the telescopic rod (505) to move the limiting sleeve (501) to the position corresponding to the end of the part. The limiting block (5024) unfolds and abuts against the inner wall of the part to fix the part. Then control the telescopic rod (505) to push the limiting sleeve (501) to move and transport the part to the worktable (801) in the working chamber (702) above the worktable (801) for precise docking at the welding station. S2, make the connecting plate (5021) slide in the limiting cavity (503) to the preset position, so that the grinding block (504) contacts the area to be welded of the welding part, and at the same time control the movable column (5022) to drive the grinding block (504) to rotate, adjust the rotation speed of the grinding block (504) and the feed amount of the connecting plate (5021), and grind and clean the area to be welded of the welding part to remove surface impurities and oxide layer; S3. The control drive component (6) is started, driving the welding part (9) to move to the welding start position, and at the same time controlling the welding part (9) to start welding according to the preset welding current, voltage and speed; during the welding process, the vision inspection unit (202) collects and transmits the weld seam image in real time, analyzes the weld seam trajectory and welding quality through the image recognition algorithm, adjusts the operating parameters of the drive component (6), and realizes automatic tracking welding of the weld seam; S4. When welding begins, start the fan in the suction port (802) and adjust it to the preset high speed. The welding fumes enter the air guide chamber (804) through the suction port (802). S5. During and after welding, the visual inspection unit (202) continuously collects weld images. The intelligent control module analyzes the width, height and flatness parameters of the weld to determine whether the weld is qualified. The vibration sensor (203) detects the vibration signal of the weld after welding to assist in judging the welding strength. S6. After welding and inspection are completed, the limiting block (5024) retracts, the telescopic rod (505) drives the limiting sleeve (501) to reset, and at the same time the worktable (801) is slightly raised, so that the operator or automated equipment can take out the welded split tee.

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