Submerged arc automatic multi-layer and multi-channel exhaust channel welding system

Abstract

The utility model relates to a submerged arc automatic multi-layer multi-channel row channel welding system which comprises an X-axis displacement module and a Y-axis displacement module, the X-axis displacement module and the Y-axis displacement module each comprise a linear sliding table, the linear sliding tables are connected with servo motors, and a laser tracker is arranged on a welding gun fixing plate; the system further comprises a PLC, the PLC is connected with a servo driver, the servo driver is electrically connected with the servo motor, and the output end of the laser tracker is connected with the analog input end of the PLC. The PLC is in communication connection with an HMI module, is provided with a wireless communication module, and is connected with a remote controller through the wireless communication module. According to the utility model, the PLC controller and the servo controller system are arranged to realize accurate control of the welding gun, the laser tracker is utilized to detect the position of a welding seam in the welding process, a hardware basis is provided for correcting the position of the welding gun, and automatic welding is realized.

Description

Technical Field

[0001] The utility model relates to the technical field of multi-layer and multi-pass welding, in particular to a submerged arc automatic multi-layer and multi-pass welding system. Background Art

[0002] Multi-pass welding refers to welding that involves depositing two or more weld layers to complete the entire weld, and each layer of the weld is completed by one weld pass. When the weld is relatively large relative to the welding process, multi-layer welding is required, and multi-layer welding often involves multiple passes.

[0003] The existing multi-layer and multi-pass welding is generally done manually or with semi-automatic welding equipment. During the welding process, the operator needs to adjust the welding gun at any time, and the welding process parameters of each layer are different. The accuracy is affected by the welding technology, the level is uneven, and the welding quality is not high.

[0004] In order to improve welding quality, an automatic welding system is urgently needed to complete multi-layer and multi-pass welding. Summary of the invention

[0005] In order to solve the problem of low quality of multi-layer and multi-pass welding operations, the utility model proposes a submerged arc automatic multi-layer and multi-pass welding system, which is equipped with a PLC controller and a servo controller system to realize precise control of the welding gun, and uses a laser tracker to detect the weld position during the welding process, providing a hardware basis for welding gun position correction, and combines the PLC controller, HMI module and remote control to realize welding control and detection, providing a hardware basis for automatic welding.

[0006] To achieve the above-mentioned purpose, the utility model proposes a submerged arc automatic multi-layer multi-pass welding system, including a welding gun mechanism, a roller frame and a cross arm manipulator, the cross arm manipulator includes an X-axis displacement module and a Y-axis displacement module, the X-axis displacement module and the Y-axis displacement module both include a linear slide, the linear slide is connected to a servo motor, the linear slide includes a slide rail and a slider, the slide rail of the X-axis displacement module is fixed to the slider of the Y-axis displacement module, the slider of the X-axis displacement module is fixedly connected to the welding gun mechanism, the welding gun mechanism includes a welding gun and a welding gun fixing plate, and a laser tracker is arranged on the welding gun fixing plate;

[0007] It also includes a PLC controller, the PLC controller is connected to a servo driver, the servo driver is electrically connected to a servo motor, and the output end of the laser tracker is connected to an analog input end of the PLC controller;

[0008] The PLC controller is communicatively connected with the HMI module, the PLC controller is provided with a wireless communication module, and the PLC controller is connected with a remote controller via the wireless communication module.

[0009] The PLC controller X-axis displacement module and Y-axis displacement module make the welding gun reciprocate in the X-axis direction and the Y-axis direction, and then combine the wire feeding device and the roller frame to complete automatic multi-layer and multi-pass welding. The laser tracker is then used to detect the weld position to improve welding accuracy and ensure welding quality.

[0010] Furthermore, a chain is provided on the slider of the X-axis displacement module, and the chain is connected to the output shaft of the servo motor through a sprocket machine, and the servo motor is arranged at the upper end of the slide rail of the Y-axis displacement module.

[0011] A drag chain is arranged between the X-axis displacement module and the Y-axis displacement module.

[0012] The chain and sprocket are arranged to facilitate the movement of the slider of the X-axis displacement module along the Y-axis direction.

[0013] Furthermore, the lead screw of the linear slide is connected to a worm gear reducer, and the other end of the worm gear reducer is connected to the output shaft of the servo motor.

[0014] The worm gear reducer is set to put the servo motor in a shaft-locking state after the servo motor stops, ensuring smooth automatic welding operations.

[0015] Furthermore, the roller frame is provided with a driving motor, the driving motor is electrically connected to a frequency converter, and the frequency converter is communicatively connected to the PLC controller.

[0016] The drive motor drives the roller frame to rotate. The operating speed of the roller frame needs to match the welding speed. The frequency converter is set to control the speed of the drive motor, providing a hardware basis for the PLC controller to automatically control the operating frequency of the roller frame.

[0017] Furthermore, the servo motor is connected to an encoder, and an output end of the encoder is connected to a servo driver.

[0018] Setting the encoder to detect the rotation parameters of the servo motor provides a hardware basis for negative feedback control.

[0019] Furthermore, the wireless communication module includes a LORA module, and the LORA module is communicatively connected to the PLC controller.

[0020] Furthermore, the remote controller is provided with a plurality of buttons, and the remote controller is communicatively connected with the PLC controller via a LORA module.

[0021] By setting up a remote control, staff can manually and remotely communicate with the PLC controller to improve the flexibility of system operations.

[0022] Furthermore, a monitor is provided near the welding gun mechanism, and the monitor is communicatively connected with the HMI module.

[0023] Setting up a monitor facilitates online monitoring of the welding condition of the weld.

[0024] Through the above technical scheme, the beneficial effects of the utility model are:

[0025] The utility model realizes multi-layer and multi-pass automatic welding, and improves welding quality and welding efficiency. A servo control system is adopted, including a servo motor, a servo driver, a PLC controller and an encoder, to improve the operation accuracy of the cross arm manipulator, so that the position adjustment of the welding gun is more accurate. A laser tracker is set near the welding gun to detect the position relationship between the welding gun and the welding point, providing a hardware basis for automatically adjusting the welding gun position. The welding effect is monitored by a monitor block, and a remote control is set to facilitate fine-tuning of the welding gun position, thereby improving the welding accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is one of the structural schematic diagrams of a submerged arc automatic multi-layer and multi-pass welding system of the utility model;

[0027] Figure 2 This is the second structural schematic diagram of a submerged arc automatic multi-layer and multi-pass welding system of the utility model;

[0028] Figure 3 The utility model is a circuit structure diagram of a submerged arc automatic multi-layer and multi-pass welding system.

[0029] Figure numbers: 1 is a welding gun mechanism, 2 is an X-axis displacement module, 3 is a Y-axis displacement module, 4 is a servo motor, 5 is a welding gun fixing plate, 6 is a laser tracker, 7 is a PLC controller, 8 is a servo driver, 9 is a chain, 10 is a remote control, 11 is a worm gear reducer, 12 is a drive motor, 13 is a frequency converter, 14 is an encoder, 15 is a LORA module, 16 is a monitor, and 17 is an HMI module. DETAILED DESCRIPTION

[0030] The utility model is further described below in conjunction with the accompanying drawings and specific embodiments:

[0031] Example 1

[0032] like Figures 1 to 3As shown, a submerged arc automatic multi-layer multi-pass welding system includes a welding gun mechanism 1, a roller frame and a cross arm manipulator, the cross arm manipulator includes an X-axis displacement module 2 and a Y-axis displacement module 3, the X-axis displacement module 2 and the Y-axis displacement module 3 both include a linear slide, the linear slide is connected to a servo motor 4, the linear slide includes a slide rail and a slider, the slide rail of the X-axis displacement module 2 is fixed to the slider of the Y-axis displacement module 3, the slider of the X-axis displacement module 2 is fixedly connected to the welding gun mechanism 1, the welding gun mechanism 1 includes a welding gun and a welding gun fixing plate 5, and a laser tracker 6 is provided on the welding gun fixing plate 5;

[0033] It also includes a PLC controller 7, the PLC controller 7 is connected to a servo driver 8, the servo driver 8 is electrically connected to a servo motor 4, and the output end of the laser tracker 6 is connected to an analog input end of the PLC controller 7;

[0034] The PLC controller 7 is communicatively connected to the HMI module 17 . The PLC controller 7 is provided with a wireless communication module. The PLC controller 7 is connected to the remote controller 10 via the wireless communication module.

[0035] Preferably, a chain 9 is provided on the slider of the X-axis displacement module 2 , and the chain 9 is connected to the output shaft of the servo motor 4 through a sprocket machine. The servo motor 4 is provided at the upper end of the slide rail of the Y-axis displacement module 3 .

[0036] A drag chain is arranged between the X-axis displacement module 2 and the Y-axis displacement module 3 .

[0037] Preferably, the lead screw of the linear slide is connected to a worm gear reducer 11 , and the other end of the worm gear reducer 11 is connected to the output shaft of the servo motor 4 .

[0038] Preferably, the roller frame is provided with a driving motor 12 , the driving motor 12 is electrically connected to a frequency converter 13 , and the frequency converter 13 is communicatively connected to the PLC controller 7 .

[0039] Preferably, the servo motor 4 is connected to an encoder 14 , and an output end of the encoder 14 is connected to a servo driver 8 .

[0040] Preferably, the wireless communication module includes a LORA module 15 , and the LORA module 15 is communicatively connected to the PLC controller 7 .

[0041] Preferably, the remote controller 10 is provided with a plurality of buttons, and the remote controller 10 is communicatively connected with the PLC controller 7 via a LORA module 15 .

[0042] Preferably, a monitor 16 is provided near the welding gun mechanism 1 , and the monitor 16 is communicatively connected with the HMI module 17 .

[0043] The PLC controller 7 is provided with a control box, and the control box is provided with function buttons. The PLC controller 7 is connected to a host computer via an RS232 serial port, and the host computer can adjust the working parameters of the PLC controller 7. After the parameters are preset by the host computer, the button is pressed and the system starts.

[0044] The PLC controller 7 controls the servo motor 4 on the X-axis displacement module 2 to work through the servo driver 8. The slider on the linear slide moves toward the weld position according to the set distance, and the welding gun moves along the X-axis. During the operation of the servo motor 4, the encoder 14 detects the rotation parameters of the servo motor 4. The PLC controller 7 determines whether the welding gun is above the working weld point through the rotation parameters (the number of rotations of the servo motor). When the welding gun reaches the set position, the servo motor 4 on the X-axis displacement module 2 is powered off and is in a locked shaft state under the action of the worm gear reducer 11.

[0045] The PLC controller 7 controls the servo motor 4 of the Y-axis displacement module 3 to work through the servo driver 8. The servo motor 4 drives the chain 9, the chain 9 extends, and the welding gun descends. At the same time, the encoder 14 detects the rotation parameters of the servo motor 4. When the welding gun reaches the welding point, the PLC controller 7 controls the servo motor 4 of the Y-axis displacement module 3 to cut off the power through the servo driver 8, and is in a shaft-locking state under the action of the worm gear reducer 11, and the chain 9 is locked.

[0046] When the welding gun contacts the workpiece, the PLC controller 7 controls the servo motor 4 on the X-axis displacement module 2 to continue working.

[0047] During straight seam welding: the laser tracker 6 scans the deviation position of the first layer of weld, and the X-axis displacement module 2 under the control of the PLC controller 7 enables the welding gun to perform the first layer of welding until the first layer of welding is completed. The laser tracker 6 scans the entire weld information, and then the PLC controller 7 detects the weld width and depth according to the laser tracker 6, and generates a welding trajectory for multi-layer welding.

[0048] During circumferential seam welding: the PLC controller 7 controls the drive motor 12 through the frequency converter 13, and the roller frame drives the welding workpiece to rotate. The PLC controller 7 combines the detection parameters of the laser tracker 6 to control the cross-arm manipulator to keep the welding gun at the welding point position. Then the PLC controller 7 detects the weld width and depth according to the laser tracker 6, and generates a multi-layer and multi-pass running trajectory. The laser tracker 6 detects the two edge positions of the weld to obtain the center point of the weld. Each layer is calibrated with a reference point through the detection parameters of the laser tracker 6, and the welding gun offset is compensated according to the reference point and the center point of the weld to complete automatic welding.

[0049] In this embodiment, the monitor 16 is a motion camera with a built-in network module. During welding, the monitor 16 performs video monitoring of the weld, and the HMI module displays parameters such as the weld video, current, arc voltage, and speed. The staff can issue control instructions to the PLC controller 7 through the HMI module.

[0050] The embodiments described above are only preferred embodiments of the present invention and are not intended to limit the scope of implementation of the present invention. Therefore, any equivalent changes or modifications made based on the structures, features and principles described in the patent scope of the present invention should be included in the patent application scope of the present invention.

Claims

1. A submerged arc automatic multi-layer multi-pass welding system, comprising a welding gun mechanism (1), a roller frame and a cross arm manipulator, wherein the cross arm manipulator comprises an X-axis displacement module (2) and a Y-axis displacement module (3), characterized in that: The X-axis displacement module (2) and the Y-axis displacement module (3) both comprise a linear slide, the linear slide is connected to a servo motor (4), the linear slide comprises a slide rail and a slider, the slide rail of the X-axis displacement module (2) is fixed to the slider of the Y-axis displacement module (3), the slider of the X-axis displacement module (2) is fixedly connected to a welding gun mechanism (1), the welding gun mechanism (1) comprises a welding gun and a welding gun fixing plate (5), and a laser tracker (6) is arranged on the welding gun fixing plate (5); It also includes a PLC controller (7), the PLC controller (7) is connected to a servo driver (8), the servo driver (8) is electrically connected to a servo motor (4), and the output end of the laser tracker (6) is connected to an analog input end of the PLC controller (7); The PLC controller (7) is communicatively connected to an HMI module (17), the PLC controller (7) is provided with a wireless communication module, and the PLC controller (7) is connected to a remote controller (10) via the wireless communication module.

2. The submerged arc automatic multi-layer multi-pass welding system according to claim 1, characterized in that: A chain (9) is arranged on the slide block of the X-axis displacement module (2), and the chain (9) is connected to the output shaft of the servo motor (4) via a sprocket machine, and the servo motor (4) is arranged on the upper end of the slide rail of the Y-axis displacement module (3); A drag chain is provided between the X-axis displacement module (2) and the Y-axis displacement module (3).

3. The submerged arc automatic multi-layer multi-pass welding system according to claim 1, characterized in that: The lead screw of the linear slide is connected to a worm gear reducer (11), and the other end of the worm gear reducer (11) is connected to the output shaft of the servo motor (4).

4. The submerged arc automatic multi-layer multi-pass welding system according to claim 1, characterized in that: The roller frame is provided with a drive motor (12), the drive motor (12) is electrically connected to a frequency converter (13), and the frequency converter (13) is communicatively connected to the PLC controller (7).

5. The submerged arc automatic multi-layer multi-pass welding system according to claim 1, characterized in that: The servo motor (4) is connected to an encoder (14), and an output end of the encoder (14) is connected to a servo driver (8).

6. The submerged arc automatic multi-layer multi-pass welding system according to claim 1, characterized in that: The wireless communication module comprises a LORA module (15), and the LORA module (15) is communicatively connected to a PLC controller (7).

7. The submerged arc automatic multi-layer multi-pass welding system according to claim 6, characterized in that: The remote controller (10) is provided with a plurality of buttons, and the remote controller (10) is communicatively connected with the PLC controller (7) via a LORA module (15).

8. The submerged arc automatic multi-layer multi-pass welding system according to claim 1, characterized in that: A monitor (16) is arranged near the welding gun mechanism (1), and the monitor (16) is communicatively connected to the HMI module (17).

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