CN102485401B - Automatic corrugated pipe welding equipment for transformer and welding method thereof - Google Patents
Automatic corrugated pipe welding equipment for transformer and welding method thereof Download PDFInfo
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- CN102485401B CN102485401B CN 201010572069 CN201010572069A CN102485401B CN 102485401 B CN102485401 B CN 102485401B CN 201010572069 CN201010572069 CN 201010572069 CN 201010572069 A CN201010572069 A CN 201010572069A CN 102485401 B CN102485401 B CN 102485401B
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Abstract
The invention relates to automatic corrugated pipe welding equipment for a transformer and a welding method thereof, and belongs to the welding technical field of a corrugated pipe for a transformer. The automatic corrugated pipe welding equipment for the transformer comprises a rotary workbench, a two-dimensional numerical control platform, a laser outline measuring instrument, an R axis, a welding machine tool and a control system; the rotary workbench is fixed on the workbench surface of the machine tool; one end of the R axis is arranged on the welding machine tool body in a sliding way, and both sides of the other end of the R axis are respectively provided with the laser outline measuring instrument and the two-dimensional numerical control platform which slides along the R axis; a welding torch is connected onto the two-dimensional numerical control platform in a sliding way; the laser of the laser outline measuring instrument is in parallel with the axis of the welding torch; the rotary workbench, the two-dimensional numerical control platform and the welding machine tool body are respectively connected with the controller of the control system through motors; and the laser outline measuring instrument is connected with the industrial computer of the control system. The automatic corrugated pipe welding equipment for the transformer and the welding method thereof solve the difficult problem of the manual welding of a large thin-wall corrugated pipe, reduce the labor intensity of a welder, improve the production efficiency, and simultaneously ensure the uniformity and the stability of the welding quality.
Description
Technical field
The invention belongs to and be applied in transformer bellows welding technology field, relate to a kind of transformer bellows welding equipment and method.
Background technology
Metal bellows all can produce the characteristics of corresponding displacement because it has under pressure, axial force, cross force or moment of flexure effect, and have many advantages such as withstand voltage, vacuum seal, corrosion-resistant, temperature stabilization and long service life, therefore obtain more and more widely application at field transformer.
In production practices, the transformer bellows is to be formed by the welding of multistage bellows and support ring, is one with other components and parts (as flange etc.) weldering often also, composition bellows class component.Bellows element axially and deviation radially all more than 20mm, welding quality is difficult to guarantee.There are shortcomings such as automaticity is low, labor strength is high, production efficiency is low, percent defective height in traditional manual welding technology.Therefore, utilize advanced control method, realize that transformer with the automatic welding of bellows, is the great technological innovation that transformer is produced with bellows, will greatly improve welding quality and the production efficiency of bellows.
Present automatic welding device, adopt the contactless CCD image sensing mostly, obtain near the image information of weld seam, carry out image by computer again and handle to obtain the needed control information of weld joint tracking, the image processing process of this method is more loaded down with trivial details, and be difficult to reach real-time and the required precision of automatic welding process, therefore not too suitable with the automatic welding of bellows for transformer.
Summary of the invention
At the technical problem of above-mentioned existence, the invention provides a kind of bellows automatic welding device and welding method thereof based on laser measuring technique, realized real-time measurement and the tracking of bellows position while welding on the basis of laser measuring technique.It is to use the laser profile measuring instrument to follow the tracks of the position coordinates that detects weld seam, can realize measuring the synchronous operation with tracing process, guarantees the automatic welding quality of bellows.
Transformer of the present invention comprises rotary table with bellows weld seam automatic welding device, the two dimension digital control platform, the laser profile measuring instrument, the R axle, welding machine tool and control system, described rotary table is fixed on the platen face, R axle one end is slidingly mounted on the lathe bed of welding machine tool, the two-dimentional digital control platform that other end both sides are separately installed with the laser profile measuring instrument and slide along the R axle, slidely connect welding gun at two-dimentional digital control platform, the laser of described laser profile measuring instrument is parallel with the welding gun axis, described rotary table, by the controller of motor connection control system, the laser profile measuring instrument is connected with the industrial computer of control system respectively for two dimension digital control platform and welding machine tool lathe bed.
Described two-dimentional digital control platform comprises first slide block and perpendicular second slide block that is slidingly connected, and first slide block and R axle are slidingly connected.Leading screw screw structure is all adopted in being slidingly connected between described R axle and bed piece, between first slide block and R between centers, first slide block and second slide block, between welding gun and second slide block, and described each leading screw all is connected with its drive motors.The leading screw two ends of described first slide block, second slide block, bed piece are respectively equipped with limit switch.
The control method of described controller comprises the steps:
1. the initial measurement zone is set in weld image preliminary treatment;
2. extract the weld signature point;
3. find the solution the welding coordinate according to least square line match principle;
4. control the motion of each motor according to the welding coordinate of finding the solution.
Transformer extracts the weld signature point with bellows weld seam automatic welding device, comprises the steps:
1. earlier weld seam is adjusted in the predefined measured zone, feature according to weld seam, tell four kinds of dissimilar weld seams respectively, namely flex point, two flex points, three flex points and more than the situation of three flex points are asked for the position while welding coordinate respectively according to these four kinds of different situations;
2. analysis image obtains the whole piece outline data by 1394 communications protocol;
3. formation mode is stored data.
Automatic soldering method of the present invention comprises the steps:
1. workpiece is installed;
2. start control system;
3. to rifle: when distance between welding gun and the weld seam is big, adjust the H axle that R axle and bed piece constitute, distance is hour between the two when R axle and lathe bed, adjust first slide block and second slide block, the position of control welding gun, when welding gun is aimed at weld seam, guarantee that first slide block and second slide block are in the stroke centre position;
4. after confirming soldering angle, specification of workpieces and welding parameter, the beginning welding processing;
5. move to next bar weld seam, carry out welding processing;
6. after all the weld seam welding is finished, withdraw from welding gun, the dismounting workpiece.
The present invention has following advantage:
(1) the present invention has realized the automatic welding of bellows by the control machinery systematic collaboration effect of controller.Can improve the production efficiency of bellows, guarantee the uniformity of welding quality.
(2) the present invention adopts the laser profile measuring instrument, to the online real-time measurement of bellows shaft section shape, has realized the accurate tracking in bellows welding slit.For the Self Adaptive Control of welding process provides technical foundation.And the laser profile measuring instrument can be at a distance, high-speed, high accuracy, measure weld seam information non-contactly, and have applied widelyly, is not subjected to characteristics such as measured material character restriction.
(3) the present invention is directed to thermal deformation in geometry deviation, seam fit-up gap error and the weldment welding process of transformer bellows weld seam, adopt the welding self-adaptation control method, this method can realize the online real-time measurement of position while welding, particularly realized the real-time calculating of position while welding, and stationarity and the reliability of the automatic welding process motion control of bellows have been guaranteed in the influence of the various interference that the system of fully taking into account may exist.
(4) automatic welding control system of the present invention has characteristics such as operation interface close friend, feature richness, operating personnel through simple training just can be on top of basic operation.A manual welding difficult problem that solves the large thin-wall bellows of the present invention has reduced welder's labour intensity, has improved production efficiency, has guaranteed uniformity and the stability of welding quality simultaneously.
(5) use automatic soldering method of the present invention and welding equipment, can realize the bellows welding of core body cylindricity 30mm, bonding wire flatness 30mm, slit 0～0.3mm, the whole free height scope of core body 800～1600mm, core body maximum weight 600kg.
Description of drawings
Fig. 1 is automatic welding device overall construction drawing of the present invention.
Fig. 2 is the mechanical schematic diagram of automatic welding device of the present invention.
Fig. 3 is control system theory diagram of the present invention.
Fig. 4 is weld bead feature points leaching process block diagram of the present invention.
Among the figure: 1. anchor clamps, 2. rotary table, 3. welding gun, 4. two-dimentional digital control platform, 5. laser profile measuring instrument, 6. lathe bed, 7. switch board, 8. bellows, 9. first slide block, 10.R axle, 11. second slide blocks.
The specific embodiment
Describe the present invention in detail below in conjunction with embodiment and accompanying drawing.
Embodiment 1: at the bellows of different size, must have 5 frees degree as the welding gun that welds device and could satisfy the requirement of operating position.Therefore, as shown in Figure 1, the present invention includes rotary table 2, two dimension digital control platform 4, laser profile measuring instrument 5, R axle 10 and welding machine tool, described rotary table 2 is fixed on the platen face, R axle 10 1 ends are slidingly mounted on the lathe bed 6 of welding machine tool, the two-dimentional digital control platform 4 that other end both sides are separately installed with laser profile measuring instrument 5 and slide along R axle 10, slidely connect welding gun 3 at two-dimentional digital control platform, the laser of described laser profile measuring instrument 5 is parallel with welding gun 3 axis, described rotary table 2, by the controller of motor connection control system, laser profile measuring instrument 5 is connected with the industrial computer of control system respectively for two dimension digital control platform 4 and welding machine tool lathe bed 6.
As shown in Figure 2, the described two-dimentional digital control platform 4 of this example comprises that first slide block 9 and perpendicular second slide block, 11, the first slide blocks 9 that are slidingly connected are slidingly connected with R axle 10.Leading screw screw structure is all adopted in being slidingly connected of 11 of 6 of described R axle 10 and bed pieces, first slide block 9 and 10 on R axle, first slide block 9 and 11 of second slide blocks, welding gun 3 and second slide blocks, and described each leading screw all is connected with its drive motors.The leading screw two ends of described first slide block 9, second slide block 11, bed piece 6 are respectively equipped with limit switch.
The course of work of the present invention:
As shown in Figure 1, the present invention is installed in bellows 8 on the rotary table 2 that constitutes the C axle when work; Welding gun 3 is installed in and constitutes on X-axis and the Z axle two dimension digital control platform 4, can follow that bellows 8 weld seams are radial and axial adjusts motion; The X-axis that first slide block 3 constitutes is radially adjusted, and the Z axle that second slide block 7 constitutes is axially adjusted.According to bellows 8 diameter variation, first slide block 3 drives second slide blocks 7 and welding gun 3 can radially done big distance movement along R axle 10; The R axle can move along bed piece 6 short transverses with the height change of different weld seams; X, Z, H and C axle in five axles are controlled by motion controller, and three of XZC realize interlock control by controller in the welding process, drive welding gun 3 and arrive the required corresponding exact position of welding jobs, and the motion of satisfying the different workpieces welding realizes needs.
Automatically the Digital Control of welding process need be considered the deviation of workpiece geometries, factors such as thermal deformation in seam fit-up gap error and the weldment welding process, control system of the present invention as shown in Figure 3, comprise interconnective controller and industrial computer, described industrial computer is connected with laser profile measuring instrument 5, controller respectively with welding gun 3, first slide block 9, second slide block 11, rotary table, drive motors on the bed piece 6 and feedback element (encoder on each drive motors) connect, feed back the position at welding gun 3 places in real time by each encoder, with the starting the arc and the movement locus of control welding gun.
The self-adaptation control method of the controller described in the present invention, adopting laser triangulation is the shaft section of the online detection bellows of laser profile measuring instrument on basis, because bellows is irregularly shaped, weld seam in dynamic rotary course extracts and exists inevitably from outside and inner interference simultaneously, and influence detects effect and the data degree of accuracy.Concrete steps are as follows:
1. weld image preliminary treatment, set the initial measurement zone: the purpose that data are handled is accurately to extract the characteristic point position of weld seam, for control and regulation provide the control data.After beginning welding, position while welding axially, the variation that do not stop of radially coordinate.In order to follow the tracks of the position of tested weld profile accurately, when measuring beginning, need the profile oscillogram on initial weld seam axially, the footpath direction limits, and sets the initial measurement zone.
2. extract the weld signature point: as shown in Figure 4, (1) earlier weld seam is adjusted in the predefined measured zone, feature according to weld seam, tell four kinds of dissimilar weld seams respectively, namely flex point, two flex points, three flex points and more than the situation of three flex points are asked for the position while welding coordinate respectively according to these four kinds of different situations;
1. the situation of a flex point: the data that namely collect in sample area have only a flex point, and the flex point coordinate namely is taken as the position coordinates at weld seam center;
2. the situation of two flex points: extract the coordinate of two flex points, the mean value that calculates at 2 is taken as the weld seam center position coordinates;
3. the situation of three flex points: the coordinate figure of three flex points relatively, the maximum of getting at 3 is the weld seam center position coordinates;
4. greater than the situation of three flex points: extract the whole maximum points in the flex point, ask they X-axis coordinate mean value and Z axial coordinate mean value as the position while welding coordinate of estimating;
(2) analysis image obtains the whole piece outline data by 1394 communications protocol;
(3) formation mode is stored data.
3. utilize least square line match principle to find the solution the welding coordinate: the weld seam coordinate that is obtained by the original measurement profile is the initial value that has error and mutability, therefore need handle detecting data, to obtain stable and continuous welding coordinate, the present invention adopts least square line match principle that the coordinate figure that detects is carried out match and prediction, can guarantee that the welding gun action is continuous, stable, velocity jump does not take place, and guarantees welding quality.
The method step that the present invention welds automatically is as follows:
1. workpiece is installed, work piece hoisting is also fixed to rotary table 2;
2. start control system: industrial computer and controller;
3. to rifle: when distance between welding gun 3 and the weld seam is big, adjust the H axle that R axle 10 and bed piece 6 constitute, distance is hour between the two when R axle 10 and lathe bed 6, adjust first slide block 9 (X-axis) and second slide block 11 (Z axle), the position of control welding gun 3, when welding gun 3 is aimed at weld seam, guarantee that first slide block 9 (X-axis) and second slide block 11 (Z axle) are in the stroke centre position;
4. by the software interface of industrial computer, after affirmation soldering angle, specification of workpieces and the welding parameter, begin welding processing;
5. move to next bar weld seam, carry out welding processing;
6. after all the weld seam welding is finished, withdraw from welding gun, the dismounting workpiece.
Use automatic soldering method of the present invention and welding equipment, can realize the bellows welding of core body cylindricity 30mm, bonding wire flatness 30mm, slit 0～0.3mm, the whole free height scope of core body 800～1600mm, core body maximum weight 600kg.
Claims (6)
1. a transformer is with bellows weld seam automatic welding device, it is characterized in that: comprise rotary table, the two dimension digital control platform, the laser profile measuring instrument, the R axle, welding machine tool and control system, described rotary table is fixed on the platen face, R axle one end is slidingly mounted on the lathe bed of welding machine tool, the two-dimentional digital control platform that other end both sides are separately installed with the laser profile measuring instrument and slide along the R axle, slidely connect welding gun at two-dimentional digital control platform, the laser of described laser profile measuring instrument is parallel with the welding gun axis, described rotary table, by the controller of motor connection control system, the laser profile measuring instrument is connected with the industrial computer of control system respectively for two dimension digital control platform and welding machine tool lathe bed; The control method of described controller comprises the steps:
1. the initial measurement zone is set in weld image preliminary treatment;
2. extract the weld signature point;
3. find the solution the welding coordinate according to least square line match principle;
4. control the motion of each motor according to the welding coordinate of finding the solution.
2. transformer according to claim 1 is with bellows weld seam automatic welding device, and it is characterized in that: described two-dimentional digital control platform comprises first slide block and perpendicular second slide block that is slidingly connected, and first slide block and R axle are slidingly connected.
3. transformer according to claim 1 is with bellows weld seam automatic welding device, it is characterized in that: leading screw screw structure is all adopted in being slidingly connected between described R axle and bed piece, between first slide block and R between centers, first slide block and second slide block, between welding gun and second slide block, and described each leading screw all is connected with its drive motors.
4. transformer according to claim 3 is with bellows weld seam automatic welding device, and it is characterized in that: the leading screw two ends of described first slide block, second slide block, bed piece are respectively equipped with limit switch.
5. transformer according to claim 1 is with bellows weld seam automatic welding device, and it is characterized in that: 2. described step extracts the weld signature point, comprises the steps:
1. earlier weld seam is adjusted in the predefined measured zone, feature according to weld seam, tell four kinds of dissimilar weld seams respectively, namely flex point, two flex points, three flex points and more than the situation of three flex points are asked for the position while welding coordinate respectively according to these four kinds of different situations;
The situation of a flex point: the data that namely collect in sample area have only a flex point, and the flex point coordinate namely is taken as the position coordinates at weld seam center;
The situation of two flex points: extract the coordinate of two flex points, the mean value that calculates at 2 is taken as the weld seam center position coordinates;
The situation of three flex points: compare the coordinate figure of three flex points, the maximum of getting at 3 is the weld seam center position coordinates;
Situation greater than three flex points: extract the whole maximum points in the flex point, ask they X-axis coordinate mean value and Z axial coordinate mean value as the position while welding coordinate of estimating;
2. analysis image obtains the whole piece outline data by 1394 communications protocol;
3. store data in the formation mode.
6. adopt transformer as claimed in claim 2 with the method for the automatic welding of bellows weld seam automatic welding device, it is characterized in that: comprise the steps:
1. workpiece is installed;
2. start control system;
3. to rifle: when distance between welding gun and the weld seam is big, adjust the H axle that R axle and bed piece constitute, distance is hour between the two when R axle and lathe bed, adjust first slide block and second slide block, the position of control welding gun, when welding gun is aimed at weld seam, guarantee that first slide block and second slide block are in the stroke centre position;
4. after confirming soldering angle, specification of workpieces and welding parameter, the beginning welding processing;
5. move to next bar weld seam, carry out welding processing;
6. after all the weld seam welding is finished, withdraw from welding gun, the dismounting workpiece.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN 201010572069 CN102485401B (en) | 2010-12-03 | 2010-12-03 | Automatic corrugated pipe welding equipment for transformer and welding method thereof |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 201010572069 CN102485401B (en) | 2010-12-03 | 2010-12-03 | Automatic corrugated pipe welding equipment for transformer and welding method thereof |
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| CN102485401A CN102485401A (en) | 2012-06-06 |
| CN102485401B true CN102485401B (en) | 2013-08-07 |
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| CN104889613B (en) * | 2015-05-15 | 2017-03-15 | 江苏金晟元特种阀门股份有限公司 | Intelligent welding technique |
| CN105195938A (en) * | 2015-10-30 | 2015-12-30 | 无锡汉神电气有限公司 | Pipe prefabrication automatic welding system |
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| CN107009066A (en) * | 2017-05-18 | 2017-08-04 | 南通世发船舶机械有限公司 | A kind of bellows-welding device |
| CN107238352B (en) * | 2017-06-01 | 2019-07-09 | 南京航空航天大学 | A kind of revolution class formation characteristic part profile laser on-machine measurement apparatus and method based on numerically controlled lathe |
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| CN109483012A (en) * | 2018-12-27 | 2019-03-19 | 济南金鲁鼎焊接技术有限公司 | Integral type bellows automatic welding device and welding method with central through hole |
| CN109894778A (en) * | 2019-03-28 | 2019-06-18 | 青岛康润源工贸有限公司 | Hoisting type roller processing unit (plant) |
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| CN112378347B (en) * | 2020-11-05 | 2022-03-08 | 中国科学院沈阳自动化研究所 | Large-scale bearing ring cylindricity measuring instrument |
| CN114046758B (en) * | 2021-11-18 | 2024-05-14 | 天津津航技术物理研究所 | Precision measuring device for special-shaped shell part |
| CN116618839B (en) * | 2023-07-20 | 2023-10-17 | 合肥三越半导体科技有限公司 | High-precision welding head alignment platform and method for corrugated pipe inner diameter welding |
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| US3918622A (en) * | 1974-03-25 | 1975-11-11 | Bailey Meter Co | Metal bellows welder |
| DE3248220A1 (en) * | 1982-12-27 | 1984-06-28 | Messer Griesheim Gmbh, 6000 Frankfurt | Welding machine for connecting two metal parts |
| JP3303256B2 (en) * | 1996-09-13 | 2002-07-15 | 三井造船株式会社 | Thick multi-layer overlay welding method and apparatus |
| JPH1110332A (en) * | 1997-06-18 | 1999-01-19 | Mitsui Eng & Shipbuild Co Ltd | Welding device |
| JP4578056B2 (en) * | 2003-02-06 | 2010-11-10 | 株式会社ダイヘン | Workpiece machining method by control system using work robot |
| CN201009042Y (en) * | 2006-10-08 | 2008-01-23 | 新疆艾特科技开发有限公司 | T type tube automatic welding machine |
| CN101839378A (en) * | 2009-03-16 | 2010-09-22 | 昆山国力真空电器有限公司 | Corrugated pipe |
| CN201913350U (en) * | 2010-12-03 | 2011-08-03 | 中国科学院沈阳自动化研究所 | Automatic welding equipment for corrugated pipes for transformers |
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