Soldering flux laying device and soldering apparatus

Abstract

The utility model discloses a kind of flux laying device and welding equipment, it is related to flux laying device technical field, wherein, flux laying device is used for the flux laying when pipeline welding, flux laying device includes flux box, partition, feed assembly, pulley connecting piece and magnetic pulley, flux box is formed with opening groove, flux box is used for slidingly attached in the pipeline to be welded, opening groove is used for towards the pipeline to be welded, partition is set in opening groove, to first cavity and second cavity are separated by opening groove, partition is formed with through-hole and first mounting hole, first mounting hole is used for the welding torch of welding machine to extend into first cavity, one end of feed assembly is provided with feeding hole, the other end of feed assembly extends into second cavity and is communicated with through-hole, to be used for welding flux is transported to first cavity, pulley connecting piece is set in flux box, magnetic pulley is rotatably set in pulley connecting piece, magnetic pulley is adsorbed to the pipeline to be welded, and magnetic pulley can roll along the outer periphery of the pipeline to be welded.

Description

Technical Field

[0001] This utility model relates to the technical field of flux laying devices, and in particular to a flux laying device and welding equipment. Background Technology

[0002] Submerged arc welding, as an efficient and economical welding process, has significant advantages over traditional gas shielded welding. Relying on high current and concentrated arc heating, it can achieve greater penetration depth, which allows for the one-time welding of thicker pipes, thereby effectively reducing the number of welding layers and joints, and greatly improving welding efficiency and speed.

[0003] In the welding process, flux coating plays a crucial role. Flux coating the welding area not only effectively isolates the air, significantly reducing common welding defects such as oxidation, gas inclusions, and cracks, and improving the mechanical properties and appearance quality of the weld, but also reduces arc radiation and the generation of harmful gases, providing strong protection for the health and safety of operators.

[0004] Most existing flux laying devices are only suitable for flat surface conditions, while the surface of the pipeline is arc-shaped. Existing flux laying devices cannot move on the pipeline surface, which means that only some areas can be covered with flux by the flux laying device, and cannot meet the requirements for flux laying of the entire pipeline.

[0005] Therefore, it is necessary to provide a new flux application device and welding equipment to solve the above-mentioned technical problems. Utility Model Content

[0006] The main purpose of this utility model is to propose a flux laying device and welding equipment, which aims to improve the technical problem that the flux laying device in the prior art is not suitable for pipeline welding.

[0007] To achieve the above objectives, according to one aspect of the present invention, a flux application device is provided for flux application during pipeline welding, comprising: A flux box having an opening groove, the flux box being slidably fitted to the pipe to be welded, the opening groove being oriented toward the pipe to be welded; A partition plate is disposed in the opening slot to divide the opening slot into a first cavity and a second cavity. The partition plate has a through hole and a first mounting hole, the first mounting hole being used for the welding torch of the welding machine to extend into the first cavity. A feeding assembly, one end of which is provided with a feeding hole, and the other end of which extends into the second cavity and communicates with the through hole, so as to convey flux to the first cavity; A pulley connector, wherein the pulley connector is disposed in the flux box; A magnetic pulley is rotatably mounted on the pulley connector. The magnetic pulley is used to attract the pipe to be welded, and the magnetic pulley can roll along the outer circumference of the pipe to be welded.

[0008] In one embodiment, the feeding assembly includes a feeding component and a conveying pipe, the conveying pipe being in communication with the through hole, and the feeding component being disposed on the conveying pipe to drive the flux in the conveying pipe through the through hole into the first cavity.

[0009] In one embodiment, the feeding assembly includes a hopper, a first elastic hose, a rigid tube, and a second elastic hose. One end of the second elastic hose is connected to the through hole. Both ends of the rigid tube are connected to the first elastic hose and the second elastic hose, respectively. The end of the first elastic hose away from the rigid tube is connected to the hopper. The feeding component is disposed on the rigid tube to drive the flux in the rigid tube into the second elastic hose and into the first cavity through the through hole.

[0010] In one embodiment, the feeding component includes a driving component and a screw-in shaft. The side wall of the rigid tube has a connecting hole, and the second elastic hose communicates with the connecting hole. One end of the screw-in shaft is connected to the driving component, and the other end of the screw-in shaft extends into the rigid tube. The screw-in shaft includes a cylindrical base and a thread spirally disposed on the cylindrical base.

[0011] In one embodiment, the driving component includes a drive motor, a first bevel gear, and a second bevel gear. The first bevel gear is rotatably disposed at one end of the rigid tube facing the second flexible hose. The screw-in shaft is connected to the first bevel gear, and the end of the screw-in shaft away from the first bevel gear extends into the rigid tube. The drive motor is disposed in the flux box, and the second bevel gear is sleeved on the output shaft of the drive motor. The first bevel gear and the second bevel gear mesh.

[0012] In one embodiment, the drive component further includes a pressure sensor and a controller. The end of the feed shaft away from the rigid tube is coaxially connected to an incremental rotary encoder via a flexible coupling for real-time detection of the rotational speed of the feed shaft. The pressure sensor is disposed on the inner wall of the rigid tube near the communicating hole for detecting the pressure inside the tube when the feed shaft pushes the flux. The encoder, the pressure sensor, and the drive motor are all signal-connected to the controller.

[0013] In one embodiment, both the first flexible hose and the second flexible hose are soft corrugated pipes.

[0014] In one embodiment, there are at least two pulley connectors and two magnetic pulleys, with the two pulley connectors respectively disposed on both sides of the flux box, and the magnetic pulleys and pulley connectors being disposed in a one-to-one correspondence.

[0015] In one embodiment, the walls of the opening slots are all fitted with mica plates.

[0016] According to another aspect of the present invention, the present invention also provides a welding device, including a welding torch, a wire feeding mechanism and the flux laying device described above. The wire feeding mechanism is used to transport the welding wire to the welding position. The flux box is formed with a second mounting hole communicating with the second cavity. The welding torch passes through the first mounting hole and the second mounting hole in sequence so that the welding torch is close to the welding bevel.

[0017] In the above scheme, the flux laying device is used for flux laying during pipeline welding. The flux laying device includes a flux box, a partition plate, a feeding assembly, a pulley connector, and a magnetic pulley. The flux box has an open slot for sliding against the pipeline to be welded. The open slot faces the pipeline to be welded. The partition plate is set in the open slot to divide the open slot into a first cavity and a second cavity. The partition plate has a through hole and a first mounting hole. The first mounting hole is used for the welding torch of the welding machine to extend into the first cavity. One end of the feeding assembly is provided with a feeding hole, and the other end of the feeding assembly extends into the second cavity and communicates with the through hole to transport flux to the first cavity. The pulley connector is set in the flux box, and the magnetic pulley is rotatably set in the pulley connector. The magnetic pulley is used to attract the pipeline to be welded, and the magnetic pulley can roll along the outer circumference of the pipeline to be welded. Specifically, the flux box is attached to the pipe to be welded, with the opening slot of the flux box facing the pipe. This allows the flux to be concentrated in the area of ​​the pipe to be welded. The partition plate is fitted with the side wall of the opening slot of the flux box, and the partition plate has a first mounting hole. The welding torch of the welding machine is inserted through the first mounting hole into the first cavity separated by the partition plate, bringing the torch close to the pipe to be welded. Flux is added through the feeding hole at one end of the feeding assembly, which then transports the flux to the other end. This end extends into the second cavity separated by the partition plate and communicates with a through hole on the partition plate. The flux enters the first cavity through the through hole. The magnetic pulley has a built-in magnet that allows it to be directly attracted to the surface of the pipe to be welded, eliminating the need for other movable clamps and avoiding scratches or deformation to the pipe surface. No complex clamps need to be adjusted before welding; the device can be quickly fixed by the magnetic pulley by simply placing it close to the pipe surface, significantly reducing positioning time. This is especially suitable for multi-pass welding or multi-station switching scenarios. During welding, the welding machine drives the welding torch to move, which in turn pushes the magnetic pulley to roll circumferentially along the pipe, achieving synchronous movement between the flux application device and the welding torch. This prevents the device from jamming or shifting position due to excessive resistance. The pulley's rolling speed is stable, ensuring that the flux output speed from the first chamber matches the device's moving speed, avoiding localized flux accumulation or insufficient coverage. This allows the flux to be applied along the welding trajectory to the entire weld joint of the pipe. The flux application device of this invention is suitable for flux application in pipelines. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1A schematic diagram of an embodiment of the flux application device provided by this utility model; Figure 2 A schematic diagram of the internal structure of an embodiment of the flux application device provided by this utility model; Figure 3 A schematic diagram showing the connection between the flux application device and the pipeline provided by this utility model; Figure 4 A schematic diagram of the internal structure of the flux application device provided by this utility model after it is connected to a pipeline.

[0020] Explanation of icon numbers: 100. Flux laying device; 1. Flux box; 11. Opening slot; 111. First cavity; 112. Second cavity; 2. Divider plate; 21. Through hole; 22. First mounting hole; 3. Material conveying assembly; 31. Feeding component; 311. Drive component; 311a. Drive motor; 311b. First bevel gear; 311c. Second bevel gear; 312. Spiral shaft; 32. Conveying pipe fitting; 321. Hopper; 322. First flexible hose; 323. Rigid pipe; 323a. Connecting hole; 324. Second flexible hose; 5. Pulley connector; 6. Magnetic pulley; 101. Welding torch.

[0021] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0022] 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 scope of protection of the present utility model.

[0023] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0024] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0025] To achieve the above objectives, according to one aspect of this utility model, please refer to... Figures 1 to 4This utility model proposes a flux laying device 100 for laying flux during pipe welding. The flux laying device 100 includes a flux box 1, a partition plate 2, a feeding assembly 3, a pulley connector 5, and a magnetic pulley 6. The flux box 1 has an opening groove 11 for sliding against the pipe to be welded. The opening groove 11 faces the pipe to be welded. The partition plate 2 is disposed in the opening groove 11 to divide the opening groove 11 into a first cavity 111 and a second cavity 112. The partition plate 2 has a through-hole. Hole 21 and first mounting hole 22, the first mounting hole 22 is used for the welding gun 101 of the welding machine to extend into the first cavity 111, one end of the material conveying component 3 is provided with a feeding hole, the other end of the material conveying component 3 extends into the second cavity 112 and communicates with the through hole 21, so as to convey the flux to the first cavity 111, the pulley connector 5 is provided on the flux box 1, the magnetic pulley 6 is rotatably provided on the pulley connector 5, the magnetic pulley 6 is used to attract the pipe to be welded, and the magnetic pulley 6 can roll along the outer periphery of the pipe to be welded. Specifically, the flux box 1 is attached to the pipe to be welded, with the opening slot 11 of the flux box 1 facing the pipe. The flux box 1 forms the opening slot 11 and is attached to the pipe to be welded, with the opening slot 11 facing the pipe, so that the flux can be concentrated in the area of ​​the pipe to be welded. The partition plate 2 is fitted with the side wall of the opening slot 11 of the flux box 1 with a clearance, and the partition plate 2 has a first mounting hole 22. The welding gun 101 of the welding machine is inserted into the first cavity 111 separated by the partition plate 2 through the first mounting hole 22, so that the welding gun 101 is close to the pipe to be welded. The flux is put into the feeding hole at one end of the feeding component 3. The flux is transported to the other end of the feeding component 3. This end extends into the second cavity 112 separated by the partition plate 2 and communicates with the through hole 21 on the partition plate 2. The flux enters the first cavity 111 through the through hole 21. The magnetic pulley 6 has a built-in magnet, which can be directly attracted to the surface of the pipe to be welded without the need for other movable clamps, thus avoiding scratches or deformation to the surface of the pipe. No complex clamps need to be adjusted before welding; the device can be quickly fixed by the magnetic pulley 6 by simply placing it close to the pipe surface, significantly reducing positioning time. This is especially suitable for multi-pass welding or multi-station switching scenarios. During welding, the welding machine drives the welding torch 101 to move, which in turn pushes the magnetic pulley 6 to roll circumferentially along the pipe, achieving synchronous movement between the flux application device 100 and the welding torch. The stable rolling speed of the magnetic pulley 6 ensures that the speed at which flux is output from the first chamber 111 matches the device's moving speed, avoiding local flux accumulation or insufficient coverage. This allows flux to be applied along the welding trajectory to the entire welding area of ​​the pipe. The flux application device 100 in this embodiment is suitable for flux application in pipelines.

[0026] Please see Figure 1 and Figure 2In one embodiment, the feeding assembly 3 includes a feeding component 31 and a feeding pipe 32. The feeding pipe 32 is connected to a through hole 21. The feeding component 31 is disposed on the feeding pipe 32 to drive the flux in the feeding pipe 32 through the through hole 21 into the first cavity 111. The direct connection between the feeding pipe 32 and the through hole 21 forms a closed channel, preventing the flux from contacting external air, dust, or contaminants on the pipe surface during the feeding process, thus reducing the risk of impurities contaminating the flux. Especially for submerged arc welding, the purity of the flux directly affects the deoxidation and slag formation effect of the weld. Closed feeding can ensure the original performance of the flux and indirectly improve the weld quality. The feeding component 31 provides active driving force, such as a screw feeder, vibratory feeder, or pneumatic pushing device. Compared with traditional passive feeding that relies on gravity, it can effectively overcome problems such as the bending of the feeding pipe 32, height difference, or poor fluidity of the flux itself, ensuring that the flux is continuously and stably fed into the first cavity 111 and avoiding insufficient flux coverage due to interruption of feeding. The driving parameters of the feeding component 31 can be adjusted according to the welding process requirements, enabling precise control of the flux delivery amount. When the welding speed is high, the power of the feeding component 31 is increased to increase the flux delivery amount and ensure sufficient coverage of the molten pool; when the welding speed is slow, the delivery amount is reduced to avoid flux accumulation and waste or obstruction of the welding torch 101's field of vision. This adjustability allows the device to adapt to welding scenarios with pipes of different thicknesses and different flux types, improving its versatility.

[0027] Please see Figure 1 and Figure 2In one embodiment, the feeding assembly 3 includes a hopper 321, a first elastic hose 322, a rigid tube 323, and a second elastic hose 324. One end of the second elastic hose 324 is connected to a through hole 21. Both ends of the rigid tube 323 are connected to the first elastic hose 322 and the second elastic hose 324, respectively. The end of the first elastic hose 322 away from the rigid tube 323 is connected to the hopper 321. A feeding component 31 is disposed on the rigid tube 323 to drive the flux in the rigid tube 323 into the second elastic hose 324 and into the first cavity 111 through the through hole 21. The hopper 321 serves as a flux storage unit, pre-filled with sufficient flux. Its bottom outlet is connected to one end of the first elastic hose 322, forming an initial channel for flux output. The flux application device 100 fits snugly against the curved surface of the pipe to be welded. One end of the second flexible hose 324 is sealed to the through hole 21 on the partition plate 2, and the other end is connected to the rigid pipe 323. The rigid pipe 323 then forms a complete conveying path with the hopper 321 through the first flexible hose 322. The feeding component 31 is located on the rigid pipe 323. After activation, it generates a directional driving force to convey the flux in the rigid pipe 323 to the second flexible hose 324, and then enters the first cavity 111 through the through hole 21. The first flexible hose 322 is flexible and can bend with slight shaking of the hopper 321 or adjustment of the overall position of the device, avoiding rigid tension that could cause breakage at the connection between the hopper 321 and the rigid pipe 323, while ensuring smooth flow of flux in the flexible channel. The rigid pipe 323, as the main trunk of the conveying path, provides rigid support and prevents excessive bending of the conveying path due to the curvature of the pipe surface or movement of the device, ensuring stable conveying of flux in a straight or controllable curved path. The flexible hose vibrates slightly during flux flow, reducing flux adhesion and accumulation on the hose wall. The rigid tube 323 has a smooth inner wall and stable path, preventing localized blockage caused by frequent changes in the flux path, making it particularly suitable for fluxes with fine particle size or high moisture content. The feeding component 31 is actively driven to overcome flow resistance. Compared to traditional passive conveying relying on gravity, the feeding component 31 provides active driving force, overcoming the flow resistance caused by the bending of the flexible hose and the length of the rigid tube 323. This ensures that the flux continues to flow over long distances or in complex paths, preventing delivery interruptions due to excessive resistance.

[0028] Please see Figure 1 and Figure 2In one embodiment, the feeding component 31 includes a driving component 311 and a screw-in shaft 312. A connecting hole 323a is provided on the side wall of the rigid tube 323. A second elastic hose 324 communicates with the connecting hole 323a. One end of the screw-in shaft 312 is connected to the driving component 311, and the other end extends into the rigid tube 323. The screw-in shaft 312 includes a cylindrical base and a helical thread disposed on the cylindrical base. Under the action of gravity, the flux in the hopper 321 enters the inlet end of the rigid tube 323 through the first elastic hose 322, forming an initial flux accumulation inside the rigid tube 323. The cylindrical base and helical thread of the screw-in shaft 312 are completely immersed in the flux. One end of the screw-in shaft 312 is connected to the external driving component 311, and the other end extends into the rigid tube 323 and extends to a position near the connecting hole 323a. The direction of the helical thread matches the flux delivery direction. The drive component 311 outputs torque, driving the advance shaft 312 to rotate around its own axis. As the spiral thread of the advance shaft 312 rotates, it generates an axial thrust on the flux within the rigid tube 323. Each thread grips the flux, converting the rotational motion into linear motion of the flux through the thread helix angle. This propels the flux along the inner wall of the rigid tube 323 from the inlet end towards the connecting hole 323a, creating a continuous columnar flow of flux within the rigid tube 323 without significant interruption. As the advance shaft 312 continues to rotate, the flux is pushed to the connecting hole 323a on the side wall of the rigid tube 323. Due to the continuous spiral thrust of the advance shaft 312, a certain pressure is created within the rigid tube 323. When it reaches the connecting hole 323a, it is laterally squeezed out from the inside of the rigid tube 323 under the pressure difference, entering the connecting hole 323a and flowing into the second elastic hose 324. The second flexible hose 324 adapts to the relative positional changes of the rigid pipe 323 and the partition plate 2 through its own flexible deformation, ensuring that the flux can still flow smoothly along the inner wall of the hose after turning, and finally enter the first cavity 111 through the through hole 21. According to the welding process requirements, the flux delivery amount can be precisely controlled by adjusting the rotation speed of the drive component 311.

[0029] The spiral thread of the screw shaft 312 forms a closed conveying unit with the inner wall of the rigid tube 323. Through the mechanical engagement of the threads with the flux, a forced propulsion force is generated for the flux, avoiding bridging, stagnation, and other blockage problems caused by poor flux flowability in traditional gravity or pneumatic conveying. Even if the flux contains a small amount of lumps, the rotation and extrusion of the spiral thread can break them up, ensuring unobstructed conveying channels.

[0030] If the connecting hole 323a is located at the end of the rigid tube 323, the flux will rush directly towards the second elastic hose 324 at a high speed under the spiral thrust. Long-term impact can easily lead to wear on the inner wall of the hose or detachment of the connection. However, the side wall connecting hole 323a allows the flux to move axially within the rigid tube 323 first, and then smoothly turn after reaching the connecting hole 323a, reducing the impact pressure on the second elastic hose 324 and extending the service life of the hose.

[0031] Please see Figure 1 and Figure 2 In one embodiment, the drive component 311 includes a drive motor 311a, a first bevel gear 311b, and a second bevel gear 311c. The first bevel gear 311b is rotatably mounted on one end of the rigid tube 323 facing the second elastic hose 324. A screw-in shaft 312 is connected to the first bevel gear 311b, with the end of the screw-in shaft 312 away from the first bevel gear 311b extending into the rigid tube 323. The drive motor 311a is mounted on the flux box 1, and the second bevel gear 311c is sleeved on the output shaft of the drive motor 311a. The first bevel gear 311b and the second bevel gear 311c mesh. Before welding begins, the drive motor 311a, which is located outside the flux box 1 or integrated into the side wall of the box, is started, and the output shaft of the drive motor 311a begins to rotate. The second bevel gear 311c is keyed or interference-fitted onto the end of the output shaft of the drive motor 311a, forming a rigid synchronous rotating body with the output shaft, transmitting the torque output by the motor to the meshing first bevel gear 311b. The first bevel gear 311b and the second bevel gear 311c are meshed, typically orthogonally meshed (i.e., the angle between their axes is 90°), but can be designed to be a non-90° angle depending on space requirements. The rotational torque of the second bevel gear 311c is transmitted to the first bevel gear 311b through tooth surface meshing, simultaneously changing the rotation direction of the output shaft of the drive motor 311a to the axial direction required by the screw-in shaft 312. The first bevel gear 311b is rotatably mounted on the end of the rigid tube 323 facing the second elastic hose 324 via a bearing, bearing the axial force of the screw-in shaft 312 while ensuring that its own rotation does not drive the rigid tube 323 to rotate synchronously. One end of the screw-in shaft 312 is rigidly connected to the hub of the first bevel gear 311b via a coupling or spline. When the first bevel gear 311b rotates, it directly drives the screw-in shaft 312 to rotate synchronously around its own axis within the rigid tube 323. The spiral thread of the advance shaft 312 rotates within the rigid tube 323, generating an axial thrust on the flux inside the tube. This propels the flux directionally from the inlet end to the outlet end of the rigid tube 323 until it reaches the connecting hole 323a. Under the continuous pushing of the advance shaft 312, the flux forms a pressurized flow within the rigid tube 323, laterally entering the second elastic hose 324 through the side wall connecting hole 323a. After a flexible transition through the hose, it finally enters the first cavity 111 through the through hole 21 on the partition plate 2, completing the filling and covering of the flux in the area to be welded. Based on process parameters such as welding speed and pipe diameter, the speed of the drive motor 311a is adjusted to match the pushing frequency of the advance shaft 312 with the flux consumption rate in the first cavity 111, ensuring continuous and uniform flux coverage.

[0032] The flux box 1 has limited space to accommodate the feeding assembly 3 and other structures. If the drive motor 311a is directly coaxially arranged with the feed shaft 312, the axial dimension of the device would be too long, or it would interfere with the opening slot 11, elastic components, and other structures in the flux box 1. By engaging the first and second bevel gears 311c, the installation direction of the drive motor 311a can be decoupled from the axial direction of the feed shaft 312, allowing the motor to flexibly choose its installation position according to the internal space of the flux box 1, avoiding conflicts with other components, and significantly reducing the overall size of the device.

[0033] During the welding process, the flow resistance of the flux in the rigid tube 323 may fluctuate due to changes in particle size, humidity fluctuations, etc. The rigid meshing of the bevel gear can provide a stable torque output, avoid transmission slippage caused by interruption of delivery, and ensure the continuity of flux delivery.

[0034] Furthermore, the drive component 311 also includes a pressure sensor and a controller. An incremental rotary encoder is coaxially connected to the end of the advance shaft 312 away from the rigid tube 323 via a flexible coupling to detect the rotational speed of the advance shaft 312 in real time. A miniature pressure sensor is embedded in the inner wall of the rigid tube 323 near the connecting hole 323a. The sensor probe is in direct contact with the flux to detect the pressure inside the tube when the advance shaft 312 pushes the flux. The signals from the encoder and pressure sensor are transmitted to the signal processing module via shielded cables. The module calculates the real-time flow rate according to a formula. The controller uses an analog PID controller. The controller receives the real-time flow rate transmitted from the signal processing module and compares it with the preset target flow rate, calculating the deviation value. The PID controller outputs a control signal based on the deviation value, driving the variable frequency drive to adjust the power supply frequency of the drive motor 311a, thereby changing the motor speed and ultimately changing the rotational speed of the advance shaft 312 to achieve the preset flow rate requirement.

[0035] Meanwhile, the controller is equipped with an OLED touch screen that can display parameters such as real-time flow rate, target flow rate, motor speed, and pipe pressure. It also supports manual input of the target flow rate or connection of an external welding speed sensor to automatically generate a preset flow rate.

[0036] To facilitate flow regulation, the thread pitch of the counterspinning feed shaft 312 gradually changes linearly from the inlet end of the rigid tube 323 to the end of the connecting hole 323a. The thread profile is rectangular, and the surface is coated with tungsten carbide to improve wear resistance.

[0037] Traditional feeding components 31 rely on a drive motor 311a to operate at a constant speed. The flow rate is affected by factors such as flux particle size, humidity, and the friction coefficient of the rigid pipe 323's inner wall, resulting in significant fluctuations. This embodiment uses an encoder to measure the rotational speed and a pressure sensor to measure the pressure inside the pipe, calculating the real-time flow rate and dynamically adjusting the motor speed using a PID controller to stabilize the flow rate. In submerged arc welding, flux flow rate fluctuations directly affect the molten pool coverage thickness. This embodiment can control the coverage thickness difference, significantly reducing the rate of welding defects such as porosity and slag inclusions.

[0038] The large thread pitch of the feed shaft 312 facing the inlet end allows for rapid flux grabbing, reducing inlet accumulation; the small thread pitch of the feed shaft 312 facing the connecting hole 323a end increases the pushing pressure, preventing outlet flow interruption due to poor flux flowability. A pressure sensor monitors the pipe pressure in real time. When the pressure exceeds the blockage threshold, the controller automatically reduces the motor speed to prevent overload damage to the rigid pipe 323 or the feed shaft 312; when P is less than the flow interruption threshold, the speed is automatically increased to replenish flux, preventing flux depletion in the first chamber 111.

[0039] Operators can directly view key parameters such as flow rate, pressure, and rotation speed via the touchscreen without disassembling the device for testing; when setting the target flow rate, manual input or automatic matching mode can be selected to reduce human calculation errors.

[0040] The tungsten carbide coating on the thread surface has a hardness more than twice that of the traditional chromium plating layer, and its service life is extended under long-term friction from the flux.

[0041] The pressure sensor probe is made of Hastelloy C-276 alloy with a polytetrafluoroethylene coating on the surface; the encoder housing has an IP67 protection rating, which can resist flux dust intrusion and extend the maintenance cycle.

[0042] In one embodiment, both the first flexible hose 322 and the second flexible hose 324 are corrugated hoses. The wall of the corrugated hose has a periodic corrugation, which reduces its bending stiffness compared to ordinary rubber hoses with smooth inner walls. In the flux laying device, the first flexible hose 322 connects the flux box 1 to the first cavity 111, and the second flexible hose 324 connects the second cavity 112 to the connecting hole. When the device moves along the circumferential / axial direction of the pipe via the magnetic pulley 6, the corrugated hose can achieve stress-free bending through corrugated compression / stretching, avoiding cracking or blockage caused by excessive bending of the hose.

[0043] Furthermore, the number of pulley connectors 5 and magnetic pulleys 6 is at least two. Two pulley connectors 5 are respectively disposed on both sides of the flux box 1, and the magnetic pulleys 6 are correspondingly disposed one-to-one with the pulley connectors 5. Multiple magnetic pulleys 6 and multiple pulley connectors 5 are configured, symmetrically distributed on both sides or above and below the flux box 1, forming a circumferential support for the outer periphery of the pipe. When the pulleys roll, they move along the tangent direction of the outer circle of the pipe, limiting the radial and circumferential displacement of the device and preventing the device from overturning or sliding due to welding vibration or external interference.

[0044] Furthermore, the pulley connector 5 is an I-shaped metal frame made of 6061 aluminum alloy, which is lightweight and high-strength. Two parallel T-shaped guide grooves are symmetrically opened on the inner side of the I-shaped metal frame. Slider assemblies are embedded in the T-shaped guide grooves. A compression spring is installed between each slider assembly and the end of the T-shaped guide groove. The two ends of the compression spring are rigidly connected to the slider and the inner wall of the guide groove respectively through spring seats, providing continuous radial preload. Each slider assembly is connected to an L-shaped mounting seat on the outside via a double-axis hinge, with the axis parallel to the pipe axis. The mounting seat can deflect around the hinge to accommodate the ellipticity or local bending of the pipe. The bottom of the L-shaped mounting seat is rotatably connected to the magnetic pulley 6 via a deep groove ball bearing. The inner ring of the bearing is interference-fitted with the pulley shaft, and the outer ring of the bearing is clearance-fitted with the hole in the L-shaped mounting seat. The rim of the magnetic pulley 6 body adopts an arc-shaped curved surface design, with a ring-shaped neodymium iron boron magnet embedded on the inner side of the curved surface. The magnet is wrapped with a 304 stainless steel sealed shell, and the surface of the shell is sprayed with a ceramic wear-resistant coating. A rubber buffer limit block is set on the outside of the T-shaped guide rail groove. When the slider slides to the maximum stroke, the slider contacts the limit block to avoid the spring being over-compressed and causing permanent deformation. At the same time, the limit block can absorb the impact vibration when the pulley rolls.

[0045] When the device is placed on pipes of different diameters, the magnetic pulley 6 is pressed against the curved surface of the pipe, pushing the L-shaped mounting base to drive the slider to slide outward along the guide rail groove. The compressed spring generates a reverse preload force, ensuring the pulley remains firmly attached to the pipe surface. For example, when the pipe diameter increases, the slider slides inward along the T-shaped guide rail groove, the spring extends, and the preload force decreases but still maintains sufficient adhesion; when the pipe diameter decreases, the slider slides outward along the guide rail groove, the spring compresses, and the preload force increases, preventing the pulley from detaching from the pipe surface. Traditional magnetic pulleys 6 require replacement with pulleys of different sizes according to the pipe diameter, resulting in a long replacement time. This embodiment, through its elastic sliding structure, automatically adapts to changes in pipe diameter without any tools, improving switching efficiency, and is particularly suitable for construction site scenarios involving welding multiple pipe specifications.

[0046] The curved surface of the rim matches the curvature of the pipe's outer circle, increasing the contact area compared to a flat rim and resulting in a more uniform distribution of adsorption force. This avoids pulley wear caused by stress concentration at a single point. When there is a local bend in the pipe, the L-shaped mounting base can deflect around a double-axis hinge, ensuring that the rim is always in tangential contact with the pipe surface and preventing sliding jamming or a sudden drop in magnetic attraction force due to angular deviation.

[0047] By rotating the adjusting nut on the spring seat, the pre-compression of the spring can be precisely controlled, thereby adjusting the adsorption force. For example, when welding thin-walled pipes, the pre-tightening force can be reduced to 50N to avoid pipe deformation; when welding thick-walled pipes, it can be increased to 200N to prevent the device from slipping.

[0048] The polytetrafluoroethylene coating on the slider surface has a friction coefficient as low as 0.02. Combined with the precision machining of the guide rail groove, the slider has low sliding resistance, ensuring smooth and uninterrupted movement of the pulley when the pipe diameter changes. At the same time, the wear-resistant cast iron slider has a long service life.

[0049] In one embodiment, the walls of the opening slot 11 are all fitted with mica sheets. Generally, the flux box 1 is made of steel. During welding, one end of the positive or negative pole of the welding machine is connected to the welding torch 101, and the other end is connected to the pipe, which enables welding. However, this circuit flows to the flux box 1, causing short circuits in other electrical components on the flux box 1 or in the welding torch 101. The mica sheets fitted to the walls of the opening slot 11 form a reliable insulation barrier due to the high insulation strength of the mica sheets, protecting precision components such as the drive motor 311a and the control system from damage caused by leakage current; at the same time, it prevents the risk of electric shock when operators accidentally touch the opening slot 11.

[0050] Furthermore, the flux laying device 100 also includes a flux recovery channel, a vibrating screening mechanism, and a closed-loop conveying assembly to achieve real-time recovery, impurity separation, and secondary utilization of scattered flux. The flux recovery channel includes an elastic scraper and a U-shaped guide trough. The elastic scraper is made of polyurethane and is installed at the bottom of the flux box 1 in front of the device's moving direction via a spring hinge. The bottom of the scraper is in contact with the surface of the pipe to be welded, and the contact pressure is adjusted by a torsion spring at the hinge. The elastic scraper has an L-shaped cross-section, with the horizontal section bolted to the bottom of the flux box 1 and the vertical section bent upwards at the end to form a catch structure to prevent flux leakage from both sides. The bent part has embedded metal reinforcing ribs to enhance wear resistance. The U-shaped guide trough is located behind the elastic scraper and is welded from 304 stainless steel plate. The trough has a U-shaped cross-section, with the bottom sloping towards the middle and a recovery port at the lowest point. The guide trough is connected to the bottom of the flux box 1 via shock-absorbing rubber pads, and the sides of the trough are fixed to the mounting frame of the magnetic pulley 6 via adjustable brackets.

[0051] The vibrating screening mechanism includes a housing, double-layer screening screens, and an eccentric vibrating motor. The housing is located on the side of the flux box 1 and is fixed by a cantilever bracket. The housing is a sealed rectangular structure with a feed inlet at the top and a clean flux outlet and an impurity outlet at the bottom. Inside the housing, double-layer removable screening screens are horizontally arranged: an upper 10-mesh coarse screen and a lower 40-mesh fine screen, with a 50mm gap between the two layers. Both layers are fixed by a snap-fit ​​frame for easy disassembly and cleaning.

[0052] The vibration drive unit includes an eccentric vibration motor and a shock-absorbing support assembly. The eccentric vibration motor is model MVE100 / 3, which is rigidly installed at the center of the bottom of the housing via a flange. Eccentric blocks are installed at both ends of the output shaft of the eccentric vibration motor.

[0053] The four corners of the bottom of the box are connected to the cantilever bracket by helical spring shock absorbers to prevent vibration from being transmitted to the flux box 1 and affecting the flux laying accuracy.

[0054] The closed-loop conveying assembly includes a miniature screw conveyor and a one-way check valve. The screw conveying unit uses a horizontal miniature screw conveyor, installed below the clean flux outlet. The conveyor inlet is connected to the impurity outlet via a flexible corrugated pipe, and the outlet extends to the recovery port at the top of the flux box 1 via an inclined conveying pipe. The conveyor is driven by a stepper motor, and its rotation speed is linked to the vibrating screening mechanism via a PLC controller.

[0055] A one-way check valve is installed between the inclined conveying pipe and the flux box 1 recovery port. It adopts a duckbill type check valve to prevent the flux in the flux box 1 from flowing back into the conveying pipe due to the tilting or vibration of the device.

[0056] As the flux application device 100 moves along the pipeline via the magnetic pulley 6, the elastic scraper at the front end of the bottom of the flux box 1 fits tightly against the pipeline surface, scraping away any unmelted flux and small amounts of slag scattered during welding and collecting them in front of the scraper. The L-shaped curved structure of the scraper guides the flux to the center, preventing leakage from both sides. Subsequently, the flux slides along the scraper surface into the U-shaped guide channel behind it. The flux entering the U-shaped guide channel flows towards the central recovery port at a 5° slope. During this process, it passes through the 2mm filter screen at the bottom of the channel, intercepting large particles with a diameter >2mm. The flux after initial screening enters the flexible corrugated pipe through the recovery port and is then conveyed to the vibrating screening mechanism.

[0057] The eccentric vibration motor starts, driving the upper 10-mesh coarse screen to separate medium impurities in the flux, and the lower 40-mesh fine screen to filter dust and micro-particle impurities; the clean flux falls to the bottom of the box and enters the screw conveyor through the clean flux outlet; impurities accumulate on the surfaces of the two screens and can be cleaned periodically by manually opening the impurity discharge outlet on the side of the box.

[0058] The screw conveyor operates intermittently according to the instructions of the PLC controller, pumping the screened clean flux through the inclined conveying pipe to the recycling inlet at the top of the flux box 1; The one-way check valve opens under the conveying pressure, and the flux enters the flux box 1 to mix with the new flux, thus achieving secondary use; when the conveyor stops, the check valve automatically closes to prevent the flux from flowing backward.

[0059] Traditional devices require manual collection of spilled flux. This embodiment uses an elastic scraper and a guide trough for real-time recovery, combined with vibrating sieve to remove impurities, which greatly improves the clean flux recovery rate and saves flux costs.

[0060] The double-layer screening mechanism can effectively separate welding slag, dust and agglomerated flux, ensuring that the flux used for recycling has uniform particle size and avoiding welding porosity and slag inclusion defects caused by impurities.

[0061] Traditional welding requires manual cleaning of the flux scattered on the pipe surface after welding. This embodiment allows the flux to be laid and collected simultaneously, reducing the amount of flux scattered on site, shortening the manual cleaning time, and preventing flux dust from flying around.

[0062] The elastic scraper achieves adaptive contact through torsion springs and spring hinges, and can automatically adjust its angle according to the ellipticity or local curvature of the pipe. The contact pressure is stable, which ensures recycling efficiency without increasing the rolling resistance of the magnetic pulley 6. The shock-absorbing design of the U-shaped guide channel prevents vibration from being transmitted to the flux box 1.

[0063] According to another aspect of this utility model, please refer to Figures 1 to 4The present invention also provides a welding device, including a welding torch 101, a wire feeding mechanism and the above-mentioned flux laying device 100. The wire feeding mechanism is used to transport the welding wire to the welding position. The flux box 1 is formed with a second mounting hole communicating with the second cavity 112. The welding torch 101 passes through the first mounting hole 22 and the second mounting hole in sequence so that the welding torch 101 is close to the welding bevel. The flux box 1 is attached to the pipe to be welded, with the opening slot 11 of the flux box 1 facing the pipe. The flux box 1 forms the opening slot 11 and is attached to the pipe, allowing the flux to be concentrated in the area of ​​the pipe to be welded. The partition plate 2 is fitted with the side wall of the opening slot 11 of the flux box 1, and the partition plate 2 has a first mounting hole 22. The welding torch 101 of the welding machine is inserted through the first mounting hole 22 into the first cavity 111 separated by the partition plate 2, bringing the welding torch 101 close to the pipe to be welded. Flux is added through the feeding hole at one end of the feeding assembly 3, and the flux is transported to its other end by the feeding assembly 3. This end extends into the second cavity 112 separated by the partition plate 2 and communicates with the through hole 21 on the partition plate 2. The flux enters through the through hole 21. Once the first cavity 111 is filled with flux, submerged arc welding can begin. The wire feeding mechanism transports the welding wire to the welding point, and the welding torch 101 welds the pipe using the welding wire and flux. Simultaneously, the flux drives the welding torch 101 to move along a preset trajectory. Since the welding torch 101 is connected to the flux placement device 100 through the first mounting hole 22, the flux placement device 100 also moves accordingly, ensuring that flux participates in the submerged arc welding reaction throughout the entire welding process. This avoids situations where there is no flux in the welding path. Furthermore, the flux is continuously consumed during welding; during this period, flux is continuously supplied to the feeding hole to ensure a continuous and stable flux supply throughout the welding process, guaranteeing the smooth progress of the welding process. Since the welding equipment includes all embodiments of the flux placement device 100 described above, it possesses at least all the beneficial effects of all the above embodiments, which will not be elaborated further here.

[0064] The above are merely exemplary embodiments of this utility model and do not limit the scope of protection of this utility model. Any equivalent structural transformations made based on the technical concept of this utility model and the contents of this utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the scope of protection of this utility model.

Claims

1. A flux application device for applying flux during pipe welding, characterized in that, include: A flux box having an opening groove, the flux box being slidably fitted to the pipe to be welded, the opening groove being oriented toward the pipe to be welded; A partition plate is disposed in the opening slot to divide the opening slot into a first cavity and a second cavity. The partition plate has a through hole and a first mounting hole, the first mounting hole being used for the welding torch of the welding machine to extend into the first cavity. A feeding assembly, one end of which is provided with a feeding hole, and the other end of which extends into the second cavity and communicates with the through hole, for conveying flux to the first cavity; A pulley connector, wherein the pulley connector is disposed in the flux box; A magnetic pulley is rotatably mounted on the pulley connector. The magnetic pulley is used to attract the pipe to be welded, and the magnetic pulley can roll along the outer circumference of the pipe to be welded.

2. The flux application device as described in claim 1, characterized in that, The material conveying assembly includes a feeding component and a conveying pipe. The conveying pipe communicates with the through hole. The feeding component is disposed on the conveying pipe to drive the flux in the conveying pipe to enter the first cavity through the through hole.

3. The flux application device as described in claim 2, characterized in that, The material conveying assembly includes a hopper, a first elastic hose, a rigid tube, and a second elastic hose. One end of the second elastic hose is connected to the through hole. Both ends of the rigid tube are connected to the first elastic hose and the second elastic hose, respectively. The end of the first elastic hose away from the rigid tube is connected to the hopper. The feeding component is disposed on the rigid tube to drive the flux in the rigid tube into the second elastic hose and into the first cavity through the through hole.

4. The flux application device as described in claim 3, characterized in that, The feeding component includes a driving component and a screw-in shaft. The side wall of the rigid tube has a connecting hole, and the second elastic hose communicates with the connecting hole. One end of the screw-in shaft is connected to the driving component, and the other end of the screw-in shaft extends into the rigid tube. The screw-in shaft includes a cylindrical base and a thread that is spirally arranged on the cylindrical base.

5. The flux application apparatus as described in claim 4, characterized in that, The driving component includes a drive motor, a first bevel gear, and a second bevel gear. The first bevel gear is rotatably disposed at one end of the rigid tube facing the second elastic flexible tube. The screw-in shaft is connected to the first bevel gear, and the end of the screw-in shaft away from the first bevel gear extends into the rigid tube. The drive motor is disposed in the flux box, and the second bevel gear is sleeved on the output shaft of the drive motor. The first bevel gear and the second bevel gear mesh.

6. The flux application apparatus as described in claim 5, characterized in that, The drive component also includes a pressure sensor and a controller. The end of the advance shaft away from the rigid tube is coaxially connected to an incremental rotary encoder via a flexible coupling to detect the rotational speed of the advance shaft in real time. The pressure sensor is set on the inner wall of the rigid tube near the connecting hole to detect the pressure inside the tube when the advance shaft pushes the flux. The encoder, the pressure sensor, and the drive motor are all signal-connected to the controller.

7. The flux application apparatus according to any one of claims 3 to 6, characterized in that, Both the first and second flexible hoses are soft corrugated pipes.

8. The flux application apparatus according to any one of claims 1 to 6, characterized in that, The number of pulley connectors and magnetic pulleys is at least two. The two pulley connectors are respectively disposed on both sides of the flux box, and the magnetic pulleys are disposed in a one-to-one correspondence with the pulley connectors.

9. The flux application apparatus according to any one of claims 1 to 6, characterized in that, The walls of the opening slots are all fitted with mica plates.

10. A welding device, characterized in that, The device includes a welding torch, a wire feeding mechanism, and a flux placement device according to any one of claims 1 to 9. The wire feeding mechanism is used to deliver the welding wire to the welding site. The flux box has a second mounting hole communicating with the second cavity. The welding torch passes through the first mounting hole and the second mounting hole in sequence to bring the welding torch close to the welding bevel.

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