Steam pipeline all-position swing electric arc narrow gap welding system

Abstract

The utility model provides a steam pipeline all-position swing electric arc narrow gap welding system which comprises a welding robot, an electric arc welding energy supply device, a control box and an interactive computer. The welding robot and the electric arc welding energy supply device are both connected with the control box and controlled by the control box, and the control box is connected with the interactive computer for remote monitoring and control of operators. A swing welding gun is connected to the welding robot, a displacement control mechanism for controlling the three-dimensional position of the swing welding gun is arranged on the welding robot, a swing motor is arranged in the swing welding gun, and a sensor assembly for monitoring the welding process is arranged on the welding robot. And a PLC (Programmable Logic Controller) is arranged in the control box. The pipeline welding device is scientific and reasonable in structural design, high in automation degree, high in welding safety efficiency and capable of fully meeting the welding operation requirements of large-diameter and medium-thick-wall pipelines.

Description

TECHNICAL FIELD

[0001] The utility model relates to a pipeline welding device, concretely relates to a steam pipeline all-position swing arc narrow gap welding system. BACKGROUND

[0002] In the field of pipeline welding, the choice of welding technology is of decisive significance to guarantee the structural integrity, operational reliability and economic efficiency of the pipeline. In the face of pipelines with different diameters and wall thicknesses, the choice of welding process shows obvious differences.

[0003] For the welding operation of small-diameter and thin-walled pipelines, traditional welding technologies such as TIG (tungsten inert gas welding) and MIG (metal inert gas welding) have occupied a dominant position due to their excellent flexibility, precise welding accuracy and excellent welding quality. These welding technologies realize precise welding of thin-walled pipelines by fine control of the arc and the supply of welding wire, effectively reducing the potential impact of heat input on the base material, thereby ensuring the mechanical properties and corrosion resistance of the pipeline.

[0004] However, when faced with the welding challenge of large-diameter and thick-walled pipelines, the limitations of traditional welding technology become apparent. In particular, the combination process of manual argon arc welding backing, welding rod arc filling and covering, although to some extent can meet the welding needs, but its disadvantages are also significant. Because thick-walled pipelines need to fill a large amount of welding material, this process not only prolongs the welding period, reduces the welding efficiency, but also increases the welding cost. In addition, welding defects introduced by human factors, such as slag inclusion, incomplete fusion, etc. will reduce the quality of the weld.

[0005] In order to cope with the limitations of traditional welding technology in the welding of large-diameter and thick-walled pipelines, narrow gap welding technology has emerged. This technology significantly reduces the amount of welding filler metal by narrowing the gap, thereby reducing welding costs and improving welding efficiency. At the same time, narrow gap welding also has the advantages of low heat input, small residual stress and slight welding deformation, which helps to maintain the geometric form and dimensional accuracy of the pipeline.

[0006] Although narrow gap welding technology has many advantages, existing narrow gap welding systems still face some problems that need to be solved. For example, the instability of welding quality is a common problem. Because narrow gap welding has high requirements for welding parameters and operating skills, any negligence may result in defects in the weld, such as incomplete penetration, inclusions, etc. In addition, the high skill requirement for operators is also a major problem in the popularization and application of narrow gap welding technology. Therefore, it is necessary to design a welding device system that can meet the welding of large-diameter and thick-walled pipelines. UTILITY MODEL CONTENT

[0007] The utility model wants to solve the technical problem in view at the above prior art, provide a steam pipeline full position swing arc narrow gap welding system, this system is designed to solve the key problems such as low efficiency, filling material consumption in the welding process of thick wall pipeline. The arc voltage change is monitored in real time by the sensor assembly, and the arc swing speed is adaptively adjusted according to the change of the weld surface morphology, so that the adaptive control of the weld surface flatness is realized, the welding is efficient and stable, the use effect is good, and the use can be promoted.

[0008] To solve the above technical problems, the utility model adopts the technical scheme: a steam pipeline full position swing arc narrow gap welding system, characterized in that, including welding robot, arc welding energy supply device, control box and interactive computer, the arc welding energy supply device connects the welding robot to provide energy for welding, the welding robot and arc welding energy supply device are connected control box and are controlled by control box, the control box is connected interactive computer and is monitored and controlled by operating personnel remotely;

[0009] The swing welding torch is connected on the welding robot, the displacement control mechanism for controlling the three-dimensional position of the swing welding torch is arranged on the welding robot, the swing motor is built-in in the swing welding torch, and the sensor assembly for monitoring the welding process is arranged on the welding robot.

[0010] The PLC controller is built-in in the control box.

[0011] The displacement control mechanism includes an electric cylinder, a lifting motor and a left-right moving motor, the electric cylinder is installed on the welding robot, the action end of the electric cylinder is fixedly connected with the lifting motor through a horizontal connecting rod, the action end of the lifting motor is flexibly connected with the swing welding torch, the electric cylinder is installed on the welding robot, the action end of the electric cylinder is fixedly connected with the lifting motor through a horizontal connecting rod, the action end of the lifting motor is fixedly connected with a lifting table, a sliding groove is formed in the lifting table, a moving table is slidably connected in the sliding groove through a sliding rail, the left-right moving motor is installed on the lifting table, the output shaft of the left-right moving motor is fixedly connected with the moving table, a mounting hole is formed in the moving table, and the swing welding torch is flexibly connected in the mounting hole. The horizontal position of the swing welding torch is controlled by the extension and contraction of the electric cylinder, the vertical position of the swing welding torch is controlled by the motor shaft movement of the lifting motor, the swing welding torch slides left and right relative to the lifting table by the push-pull of the left-right moving motor, and then the swing welding torch swings left and right by the swing motor in the swing welding torch, so that the position of the swing welding torch in the three-dimensional space is flexibly adjusted, and the weld is fully covered.

[0012] Preferably, the sensor assembly comprises a visual sensor for monitoring the surface morphology and position of the weld seam in real time and an electrical signal sensor, which is a voltage sensor, for monitoring the arc voltage variation of the welding arc in real time, both of which are connected to the signal input port of the PLC controller, the control signal output port of the PLC controller is connected to the welding robot, the electric cylinder, the lifting motor, the swing welding gun and the swing motor, and the power supply port of the PLC controller is connected to the arc welding energy supply device.

[0013] Preferably, the welding parameter requirements and the swing path of the swing welding gun are programmed in the PLC controller. The control signal output port of the PLC controller is also connected to the electric cylinder, the lifting motor and the left-right moving motor. The PLC control system generates corresponding pulse instructions according to the control signals, and the servo driver generates corresponding pulse quantities to drive the actuator to make corresponding actions.

[0014] The utility model has the following advantages compared with prior art:

[0015] 1. The utility model discloses a sensor assembly for real-time monitoring of the arc state and self-adaptive adjustment of the welding parameters, effectively solving the problems of low efficiency and large material consumption in thick-walled pipeline welding. At the same time, the control device is provided, which can move the welding gun in three dimensions, meeting the demand of all-position welding of complex pipeline structure. The PLC controller can real-time receive the welding seam information and arc voltage information collected by the sensor assembly, timely adjust the welding gun position and swing amplitude frequency, and the staff can also obtain the welding information in time through the interactive computer, ensure the welding quality on the basis of remote control detection and control, and jointly constitute an automatic control system, reduce manual intervention and improve the welding efficiency.

[0016] 2. The utility model discloses a swing motor arranged in the swing welding gun, which ensures the relative stability of the arc in the welding process through the angular swing mode, and guarantees the fusion quality of the pipeline wall. The swing frequency and amplitude of the swing motor can be set according to different welding requirements and material characteristics.

[0017] The utility model will be further described in detail in combination with the drawings and examples. DRAWINGS

[0018] Fig. 1 It is the overall architecture schematic diagram of the utility model.

[0019] Fig. 2 It is the connection structure schematic diagram of the welding robot and the swing welding gun in the utility model.

[0020] Fig. 3 It is the schematic diagram of the working end of the swing welding gun in the utility model.

[0021] Reference numerals:

[0022] 1 - arc welding energy supply 2 - welding robot; 3 - control box;

[0023] Device;

[0024] 4 - interactive computer; 5 - sensor assembly; 6 - swing welding gun; 7 - horizontal connecting rod; 8 - lifting platform; 9 - lifting motor; 10 - welding workpiece. DETAILED DESCRIPTION

[0025] As Figs. 1 to 3 shown, the utility model includes welding robot 2, arc welding energy supply device 1, control box 3 and interactive computer 4, arc welding energy supply device 1 connects welding robot 2 and provides energy for welding, welding robot 2 and arc welding energy supply device 1 all are connected control box 3 and are controlled by control box 3, control box 3 connects interactive computer 4 and is monitored and controlled by operating personnel remotely, swing welding gun 6 is connected on welding robot 2, displacement control mechanism that controls swing welding gun 6 three-dimensional position is provided on welding robot 2, swing motor is built-in in swing welding gun 6, sensor assembly 5 that monitors welding process is provided on welding robot 2, PLC controller is built-in in control box 3.

[0026] The displacement control mechanism includes electric cylinder, lifting motor and left and right moving motor, electric cylinder is installed on welding robot 2, the action end of electric cylinder is fixedly connected lifting motor 9 through horizontal connecting rod 7, the action end of lifting motor 9 is flexibly connected swing welding gun 6, electric cylinder is installed on welding robot 2, the action end of electric cylinder is fixedly connected lifting motor 9 through horizontal connecting rod 7, the action end of lifting motor 9 is fixedly connected lifting platform 8, the sliding slot is set up on lifting platform 8, moving platform is slidably connected in the sliding slot through slide rail, left and right moving motor is installed on lifting platform 8, the output shaft of left and right moving motor is fixedly connected moving platform, the mounting hole is set up on moving platform, swing welding gun 6 is flexibly connected in the mounting hole, swing welding gun 6 is flexibly sealedly connected at both ends of mounting hole, flexible material is filled in mounting hole, and the swing welding gun 6 is flexibly connected to avoid affecting the swing movement of swing welding gun 6. The horizontal position change of swing welding gun 6 is controlled by the telescopic electric cylinder, the vertical position change of swing welding gun 6 is controlled by the motor shaft movement of lifting motor 9, swing welding gun 6 is made to slide left and right relative to lifting platform 8 by the push and pull of left and right moving motor, then swing welding gun 6 is made to swing left and right by the swing motor in swing welding gun 6, the position change of swing welding gun 6 in three-dimensional space is flexibly adjusted, and full coverage of weld is realized.

[0027] In the embodiment, the sensor assembly 5 includes a visual sensor for monitoring the surface morphology and position of the weld in real time and an electrical signal sensor, which is a voltage sensor for monitoring the arc voltage change of the welding arc in real time, both of which are connected to the signal input port of the PLC controller, the control signal output port of the PLC controller is connected to the welding robot 2, the electric cylinder, the lifting motor 9, the swing welding torch 6 and the swing motor, and the power port of the PLC controller is connected to the arc welding energy supply device 1.

[0028] In the embodiment, the embedded welding parameter requirements and the swing path of the swing welding torch 6 are programmed in the PLC controller. The control signal output port of the PLC controller is connected to the electric cylinder, the lifting motor and the left-right moving motor through a pulse generator. The PLC controller generates corresponding pulse instructions according to the control signal, and the pulse generator generates corresponding pulse quantities according to the instructions to drive each actuator to make corresponding actions.

[0029] In the embodiment, the interactive computer 4 displays the information collected by the visual sensor in real time, which facilitates the observation and monitoring of the staff, and a control instruction input panel is arranged on the interactive computer 4, so that the staff can intervene in the welding operation by means of remote control to adjust the welding path and parameters.

[0030] In the embodiment, when the welding workpiece 10 with a medium-thick U-shaped groove is welded, the welding robot 2 is controlled by the PLC controller to reach the specified station, the horizontal position of the swing welding torch 6 is adjusted by the PLC controller according to the position information of the welding workpiece 10 transmitted by the visual sensor, the vertical position of the swing welding torch 6 is controlled by the PLC controller through the lifting motor 9, and the left-right position of the swing welding torch 6 is controlled by the PLC controller through the left-right moving motor, until the welding head of the swing welding torch 6 is in a reasonable welding position, the swing welding torch 6 is started to begin welding by the arc welding energy supply device 1, the surface morphology and position of the weld are monitored in real time by the visual sensor during the welding process, the arc voltage change is detected by the electrical signal sensor, the swing amplitude and frequency of the swing motor are controlled by the PLC controller according to the preset welding path and welding parameter requirements, and the moving position and speed of the swing welding torch 6 in the next step are further adjusted by the PLC controller in combination with the surface morphology and position information of the weld, so that the welding work of the welding workpiece 10 with a medium-thick U-shaped groove is finally completed safely, efficiently and stably. The staff can monitor the welding operation process through the interactive computer 4 during the welding operation process, and can intervene in time when necessary.

[0031] The above is only a preferred embodiment of the present application, and does not limit the present application in any way. Any simple modification, change and equivalent change made to the above embodiment according to the technical essence of the present application still falls within the protection scope of the technical solution of the present application.

Claims

1. A steam pipe all-position, oscillating arc, narrow gap welding system characterized by, The application relates to a welding robot (2), an arc welding energy supply device (1), a control box (3) and an interactive computer (4), wherein the arc welding energy supply device (1) is connected with the welding robot (2) to provide energy for welding, the welding robot (2) and the arc welding energy supply device (1) are both connected with the control box (3) to be controlled by the control box (3), and the control box (3) is connected with the interactive computer (4) to be remotely monitored and controlled by an operator. The welding robot (2) is connected with a swing welding gun (6), the welding robot (2) is provided with a displacement control mechanism for controlling the three-dimensional position of the swing welding gun (6), the swing welding gun (6) is internally provided with a swing motor, and the welding robot (2) is provided with a sensor assembly (5) for monitoring a welding process; the displacement control mechanism comprises an electric cylinder, a lifting motor (9) and a left-right moving motor, the electric cylinder is installed on the welding robot (2), the action end of the electric cylinder is fixedly connected with the lifting motor (9) through a horizontal connecting rod (7), the action end of the lifting motor (9) is fixedly connected with a lifting platform (8), the lifting platform (8) is slidably connected with a moving platform, the lifting platform (8) is provided with the left-right moving motor for controlling the left-right sliding of the moving platform, and the moving platform is flexibly connected with the swing welding gun (6). The control box (3) is internally provided with a PLC controller.

2. A steam conduit all-position oscillating electric arc narrow gap welding system according to claim 1, characterized in that, The PLC control system generates corresponding pulse instructions according to control signals, a servo driver receives the instructions to generate corresponding pulse quantities, and an executing mechanism is driven to make corresponding actions.

3. A steam conduit all-position oscillating electric arc narrow gap welding system according to claim 1, characterized in that, The sensor assembly (5) comprises a visual sensor and an electric signal sensor, the visual sensor and the electric signal sensor are both connected with a signal input port of the PLC controller, a control signal output port of the PLC controller is connected with the welding robot (2), the electric cylinder, the lifting motor (9), the swing welding gun (6) and the swing motor, and a power supply port of the PLC controller is connected with the arc welding energy supply device (1).

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