Large-diameter flexible tube plate welding deformation control system

Abstract

The utility model relates to the technical field of welding, and discloses a large-diameter flexible tube plate welding deformation control system which comprises a shell pass barrel and a flexible tube plate, the periphery of the flexible tube plate forms an annular folded edge through circular arc smooth transition, and the two ends of the shell pass barrel are welded and fixed to the annular folded edge of the flexible tube plate respectively. A tube head welding area is arranged in the middle of the flexible tube plate, and each tube hole of the tube head welding area is welded with the end head of the heat exchange tube; the supporting mechanism is used for supporting the flexible tube plate; the preheating device is used for preheating the welding area; and the monitoring control system is used for monitoring the temperature and deformation of the flexible tube plate. According to the utility model, the flexible tube plate is rigidly supported, the flexible tube plate is preheated in different areas before welding, the temperature field and the stress field of the flexible tube plate are monitored in real time by using the monitoring control system in the welding process, and the welding sequence and the welding position are adjusted in time according to the data; the accuracy and the high efficiency of welding deformation control are greatly improved, and the welding quality and the production efficiency are improved.

Description

Technical Field

[0001] This utility model belongs to the field of welding technology and relates to large-diameter flexible tube sheets, specifically a welding deformation control system for large-diameter flexible tube sheets. Background Technology

[0002] During the welding process of large-diameter flexible tube sheets, uneven heating and cooling in the weld area can easily lead to significant welding deformation, resulting in decreased dimensional accuracy and reduced structural strength. Traditional methods for controlling welding deformation, such as rigid fixing or reserving anti-deformation allowances, have limited effectiveness in large-diameter flexible tube sheets and are complex and costly, failing to meet current welding requirements.

[0003] Therefore, there is an urgent need to develop an efficient and precise welding deformation control system to meet the welding requirements of large-diameter flexible tube sheets. Utility Model Content

[0004] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a welding deformation control system for large-diameter flexible tube sheets. By using the coordinated action of multiple devices, the system reduces the concentration of thermal stress during the welding process, thereby controlling the deformation of the flexible tube sheet.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a large-diameter flexible tube sheet welding deformation control system, comprising a shell-side cylinder and a flexible tube sheet, wherein the periphery of the flexible tube sheet is smoothly transitioned by an arc to form an annular folded edge, and both ends of the shell-side cylinder are welded and fixed to the annular folded edge of the flexible tube sheet respectively; the middle of the flexible tube sheet is a tube head welding area, and each tube hole in the tube head welding area is welded to the end of a heat exchange tube; further comprising:

[0006] The support mechanism includes a support ring and reinforcing ribs. The support ring is welded to the annular folded edge of the flexible tube sheet. Reinforcing ribs are evenly distributed along the circumference of the flexible tube sheet. One end of the reinforcing rib is welded and fixed to the support ring and welded to the arc area of ​​the flexible tube sheet through an arc groove.

[0007] A preheating device, which is detachably fixed to the periphery of the welding circumference between the shell-side cylinder and the flexible tube sheet, as well as the tube head welding area of ​​the flexible tube sheet.

[0008] The monitoring and control system includes a temperature sensor for real-time monitoring of the temperature of the flexible tube sheet and a strain sensor for real-time monitoring of the deformation of the flexible tube sheet; the temperature sensors are spaced apart in the tube head welding area of ​​the flexible tube sheet; the strain sensors are detachably connected to the outer periphery of the flexible tube sheet.

[0009] As a further technical solution, the tube holes on the tube head welding area of ​​the flexible tube sheet, which are used as self-support areas, are first welded to the heat exchange tubes to provide self-support during welding.

[0010] As a further technical solution, the shell-side cylinder and the flexible tube sheet are fixed by two welding methods: semi-welding and full welding; the semi-welding is 1 / 3 of the height of the weld seam.

[0011] As a further technical solution, the preheating device consists of a heating element and an insulating asbestos mesh; the insulating asbestos mesh covers the heating element.

[0012] As a further technical solution, the heating element is selected as a resistance wire preheating ring or an electromagnetic induction preheating coil.

[0013] The welding process of a large-diameter flexible tube sheet welding deformation control system is as follows:

[0014] S1. Weld the support ring to the annular fold of the flexible tube sheet, and then weld the reinforcing rib plate. The reinforcing rib plate is evenly welded to the arc area of ​​the flexible tube sheet through the arc groove. The reinforcing rib plate contacts the surface of the support ring and is welded and fixed to strengthen the support.

[0015] S2. Install the preheating device: Use iron wire to fix the electromagnetic induction preheating coil around the welded annular seam between the flexible tube sheet and the shell-side cylinder, and then cover the electromagnetic induction preheating coil with thermal insulation asbestos mesh.

[0016] S3. Weld the circumferential weld between the flexible tube sheet and the shell-side cylinder. First, weld 1 / 3 of the weld height to avoid deformation of the flexible tube sheet during welding, and at the same time, use the rigidity of the shell-side cylinder to further support the flexible tube sheet.

[0017] S4. Insert the heat exchange tubes through the tube head welding area of ​​the flexible tube sheet into the shell-side cylinder. At this time, both ends of the heat exchange tubes are inserted into all the tube holes in the tube head welding area.

[0018] S5. The temperature sensor is uniformly connected to the surface of the flexible tube sheet by spot welding.

[0019] S6. Magnetically attach the strain sensor evenly to the outer periphery of the flexible tube sheet.

[0020] S7. Install the preheating device: Use iron wire to fix the electromagnetic induction preheating coil to the welding area of ​​the flexible tube sheet, then cover the electromagnetic induction preheating coil with thermal insulation asbestos mesh, and preheat the welding area by turning on the power.

[0021] S8. When welding the heat exchange tubes, first remove the preheating device in the welding area, and then carry out the welding operation; use this part of the heat exchange tube as a tie rod to rigidly fix the entire flexible tube sheet.

[0022] S9. Weld the remaining pipe ends, proceeding from the center outwards in sections; similarly, the preheating device in the welding area should be removed before welding.

[0023] It is important to note that the monitoring and control system will monitor the temperature and deformation of the flexible tube sheet in real time, and adjust the welding area accordingly. When the temperature of the flexible tube sheet exceeds the limit or there is slight deformation, the temperature sensor or strain sensor will send a signal. Upon receiving the signal, the staff will change the welding area to avoid excessive local stress and deformation. Typically, one end of the tube sheet is welded before the other end is welded, and the two ends are welded alternately to reduce deformation and gradually strengthen the rigid fixation of the flexible tube sheet.

[0024] After the tube head welding is completed in S10, the weld circumferential seam between the flexible tube sheet and the shell-side cylinder in S3 is then fully welded to achieve fixation.

[0025] S11. Remove all equipment other than the shell-side cylinder, flexible tube sheet, and heat exchange tubes (support ring, reinforcing ribs, preheating device, temperature sensor, strain sensor), and complete the welding of the large-diameter flexible tube sheet.

[0026] Compared with the prior art, the beneficial effects of this utility model are:

[0027] Compared with traditional methods, this invention has significant advantages in terms of shape control mechanism, equipment coordination, and operation management. By providing rigid support to the flexible tube sheet, preheating the flexible tube sheet in sections before welding, and using a monitoring and control system to monitor the temperature and stress fields of the flexible tube sheet in real time during welding, the welding sequence and position are adjusted in a timely manner based on this data. This greatly improves the accuracy and efficiency of welding deformation control, thereby improving welding quality and production efficiency. Attached Figure Description

[0028] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0029] Figure 1 This is a schematic diagram of the structure of this utility model.

[0030] Figure 2 This is a side view of the present invention.

[0031] In the figure, 1-shell side shell, 2-flexible tube sheet, 21-annular fold, 22-tube head welding area, 3-supporting ring, 4-reinforcing rib, 41-arc groove, 5-heat exchange tube, 6-preheating device, 7-temperature sensor, 8-strain sensor; A-welding circumferential seam. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] Example: Reference Figure 1-2 The large-diameter flexible tube sheet welding deformation control system shown includes a shell-side cylinder 1 and a flexible tube sheet 2. The periphery of the flexible tube sheet 2 is smoothly transitioned by an arc to form an annular folded edge 21. The two ends of the shell-side cylinder 1 are welded and fixed to the annular folded edge 21 of the flexible tube sheet 2. The middle of the flexible tube sheet 2 is a tube head welding area 22, and each tube hole in the tube head welding area 22 is welded to the end of the heat exchange tube 5. It also includes: a support mechanism for reinforcing the flexible tube sheet 2; a preheating device 6 for preheating the welding area; and a monitoring and control system for monitoring the temperature and deformation of the flexible tube sheet.

[0034] 1. Supporting institutions

[0035] The support mechanism includes a support ring 3 and a reinforcing rib 4. The support ring 3 is welded to the annular folded edge 21 of the flexible tube sheet 2. The flexible tube sheet 2 is evenly distributed with reinforcing ribs 4 along the circumference. One end of the reinforcing rib 4 is welded and fixed to the support ring 3 and welded to the arc area of ​​the flexible tube sheet 2 through the arc groove 41.

[0036] Specifically, the shell-side cylinder 1 and the flexible tube sheet 2 are fixed by two welding methods: half welding and full welding. The first welding is a half welding state, welding only 1 / 3 of the weld height, using the rigidity of the equipment material itself to support the flexible tube sheet. The second welding is the remaining part, thus fixing the shell-side cylinder 1 and the flexible tube sheet 2.

[0037] Specifically, heat exchange tube 5 is welded to flexible tube sheet 2 in two stages; the first weld is as follows: Figure 2 The heat exchange tube 5, located in the black area, acts as a tie rod, providing self-support and rigidly fixing the entire flexible tube sheet; all tube ends are welded a second time.

[0038] 2. Preheating device

[0039] The preheating device 6 is detachably fixed around the weld circumference of the shell-side cylinder 1 and the flexible tube sheet 2, as well as the tube head welding area 22 of the flexible tube sheet 2.

[0040] Specifically, the preheating device 6 consists of an electromagnetic induction preheating coil and an insulating asbestos mesh, with the insulating asbestos mesh covering the electromagnetic induction preheating coil; it can uniformly preheat the flexible tube sheet and reduce the thermal stress during welding.

[0041] 3. Monitoring and Control System

[0042] The monitoring and control system includes a temperature sensor 7 that monitors the temperature of the flexible tube sheet in real time and a strain sensor 8 that monitors the deformation of the flexible tube sheet in real time.

[0043] Specifically, temperature sensors 7 are spot-welded at intervals in the tube head welding area 22 of the flexible tube sheet 2 (position distribution as shown in the figure). Figure 2 (As shown). The strain sensor 8 is magnetically attached to the outer periphery of the flexible tube sheet 2 (position distribution as shown). Figure 2 (As shown).

[0044] refer to Figure 1-2 The welding deformation control system for a large-diameter flexible tube sheet shown is described below, and its welding process is as follows:

[0045] S1. Weld the supporting ring 3 to the annular folded edge 21 of the flexible tube sheet 2, and then weld the reinforcing rib plate 4; the reinforcing rib plate 4 is evenly welded to the arc area of ​​the flexible tube sheet 2 through the arc groove 41 (position distribution as shown in the figure). Figure 2 As shown, the reinforcing rib 4 contacts the surface of the supporting ring 3 and is welded and fixed to strengthen the support.

[0046] S2. Install the preheating device: Use iron wire to fix the electromagnetic induction preheating coil around the welded circumference between the flexible tube sheet 2 and the shell-side cylinder 1, and then cover the electromagnetic induction preheating coil with thermal insulation asbestos mesh.

[0047] S3, the welded circumferential joint between the flexible tube sheet 2 and the shell-side cylinder 1 (location as shown in the figure). Figure 1 As shown in the figure, weld 1 / 3 of the weld height first to avoid deformation of the flexible tube sheet 2 during welding, and at the same time use the rigidity of the shell-side cylinder 1 to further support the flexible tube sheet 2.

[0048] S4. Insert the heat exchange tube 5 through the tube head welding area 22 of the flexible tube sheet 2 into the shell-side cylinder 1. At this time, both ends of the heat exchange tube 5 are inserted into all the tube holes of the tube head welding area 22.

[0049] S5. The temperature sensor 7 is evenly connected to the surface of the flexible tube sheet 2 by spot welding, such as... Figure 2 As shown.

[0050] S6. Magnetically attach the strain sensor 8 uniformly to the outer periphery of the flexible tube sheet 2, with the positions distributed as follows: Figure 2 As shown.

[0051] S7. Install the preheating device: Use iron wire to fix the electromagnetic induction preheating coil to the welding area 22 of the flexible tube sheet 2, and then cover the electromagnetic induction preheating coil with thermal insulation asbestos mesh, and preheat the welding area by turning on the power.

[0052] S8. When welding heat exchange tube 5, first remove the preheating device 6 within the welding area, and then proceed with the welding operation; the location distribution is as follows: Figure 2 As shown in the black area, this part of the heat exchange tube 5 acts as a tie rod to rigidly fix the entire flexible tube sheet 2.

[0053] S9. Weld the remaining pipe ends, proceeding from the center outwards in sections; similarly, the preheating device in the welding area should be removed before welding.

[0054] It is important to note that the monitoring and control system will monitor the temperature and deformation of the flexible tube sheet 2 in real time, and adjust the welding area accordingly. When the temperature of the flexible tube sheet 2 exceeds the limit or there is slight deformation, the temperature sensor 7 or strain sensor 8 will send a signal. Upon receiving the signal, the operator will change the welding area to avoid excessive local stress and deformation. Typically, one end of the tube sheet is welded before the other end is welded, and the two ends are welded alternately to reduce deformation and gradually strengthen the rigid fixation of the flexible tube sheet 2.

[0055] After the tube head welding is completed in S10, the weld circumferential seam between the flexible tube sheet 2 and the shell-side cylinder 1 in S3 is fully welded to achieve fixation.

[0056] S11. Remove all other equipment except shell-side cylinder 1, flexible tube sheet 2 and heat exchange tube 5 (support ring 3, reinforcing rib 4, preheating device 6, temperature sensor 7, strain sensor 8) to complete the welding of the large-diameter flexible tube sheet.

[0057] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A large-diameter flexible tube sheet welding deformation control system, comprising a shell-side cylinder (1) and a flexible tube sheet (2), wherein the periphery of the flexible tube sheet (2) is formed by a smooth arc transition to form an annular fold (21), and both ends of the shell-side cylinder (1) are welded and fixed to the annular fold (21) of the flexible tube sheet (2); the middle of the flexible tube sheet (2) is a tube head welding area (22), and each tube hole in the tube head welding area (22) is welded to the end of a heat exchange tube (5); characterized in that: Also includes: The support mechanism includes a support ring (3) and a reinforcing rib (4). The support ring (3) is welded to the annular fold (21) of the flexible tube sheet (2). The flexible tube sheet (2) is evenly distributed with reinforcing ribs (4) along the circumference. One end of the reinforcing rib (4) is welded and fixed to the support ring (3) and welded to the arc area of ​​the flexible tube sheet (2) through an arc groove (41). Preheating device (6), which is detachably fixed to the periphery of the welding circumference between the shell side cylinder (1) and the flexible tube sheet (2) and the tube head welding area (22) of the flexible tube sheet (2). The monitoring and control system includes a temperature sensor (7) for real-time monitoring of the temperature of the flexible tube sheet and a strain sensor (8) for real-time monitoring of the deformation of the flexible tube sheet; the temperature sensor (7) is spaced apart in the tube head welding area (22) of the flexible tube sheet (2); the strain sensor (8) is detachably connected to the outer periphery of the flexible tube sheet (2).

2. The welding deformation control system for large-diameter flexible tube sheet according to claim 1, characterized in that: The tube hole in the tube head welding area (22) of the flexible tube sheet (2) is used as a self-supporting area to be welded to the heat exchange tube (5) first, so as to provide self-support during welding.

3. The welding deformation control system for large-diameter flexible tube sheet according to claim 1, characterized in that: The shell-side cylinder (1) and the flexible tube sheet (2) are fixed by two welding methods: half welding and full welding. The half welding is 1 / 3 of the height of the weld.

4. The welding deformation control system for large-diameter flexible tube sheet according to claim 1, characterized in that: The preheating device (6) consists of a heating element and an insulating asbestos mesh; the insulating asbestos mesh covers the heating element.

5. The welding deformation control system for large-diameter flexible tube sheet according to claim 4, characterized in that: The heating element is selected from resistance wire preheating rings or electromagnetic induction preheating coils.

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