CN107030446B - Online repair system for sealing surface of high-temperature and high-pressure steam valve - Google Patents
Online repair system for sealing surface of high-temperature and high-pressure steam valve Download PDFInfo
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- CN107030446B CN107030446B CN201710289352.7A CN201710289352A CN107030446B CN 107030446 B CN107030446 B CN 107030446B CN 201710289352 A CN201710289352 A CN 201710289352A CN 107030446 B CN107030446 B CN 107030446B
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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- B23P6/00—Restoring or reconditioning objects
Abstract
The invention discloses an online repair system for a sealing surface of a high-temperature and high-pressure steam valve, which comprises a mobile robot TIG welding system, a heat treatment system and a digital display grinding device which are connected with each other; the movable TIG welding system of the robot comprises a welding gun head, a welding gun barrel, a wire drawing device, a guide wheel, a tension spring, a support frame, a wire feeding pipe, a water-cooled cable, a guide rod, a straightener, a wire feeding disc, a wire feeding machine, a TIG power supply, a wire feeding support, a movable universal wheel, a robot base, a first robot shaft, a second robot shaft, a third robot shaft, a fourth robot shaft, a fifth robot shaft, a sixth robot shaft, a tungsten electrode, a clamping piece and a high-temperature camera, wherein the TIG power supply is connected with the guide rod through the water-cooled cable, and the two guide rods are arranged at the top end of the wire feeding support. The method has the characteristics of excellent quality after repair, high repair efficiency, low cost of the whole repair and good economy.
Description
Technical Field
The invention relates to an online repair system for a sealing surface, in particular to an online repair system for a sealing surface of a high-temperature and high-pressure steam valve.
Background
The high-temperature high-pressure steam valve is complex in specification, narrow in repair space and numerous in number, so that the requirement of general supporting equipment which can adapt to the high-temperature high-pressure steam valve in the whole range is not met in the industry at present. In the field maintenance process, the existing equipment can not directly build up the hard alloy, and only adopts the build up ERNiCrMo-3 (nickel base) to repair the hard alloy. However, the nickel-based overlay welding layer has only a hardness of HB =180, and cannot have a certain "red hardness", that is, the surface hardness of the sealing surface needs to reach about HRC 35 to 40, so as to ensure the wear resistance and the erosion resistance. Therefore, the development of a method and equipment with high automation degree and low dilution rate of surfacing is an urgent problem to be solved at present. Aiming at the defects of the sealing surface of the steam valve, the invention realizes the online repair of the sealing surface of the high-temperature high-pressure steam valve by the automatic surfacing of the wear-resistant layer, the preheating before and after the surfacing and the high-temperature tempering, and the high-precision machining of the surfacing layer, thereby ensuring the tightness of the valve and improving the reliability and the economy of system equipment.
Disclosure of Invention
The invention aims to provide an online repairing system for a sealing surface of a high-temperature and high-pressure steam valve, which has the characteristics of excellent quality after repairing, high repairing efficiency and low whole repairing cost.
The invention solves the technical problems through the following technical scheme: an online repair system for a sealing surface of a high-temperature and high-pressure steam valve is characterized by comprising a mobile robot TIG welding system, a heat treatment system and a digital display grinding device which are connected with each other;
the TIG welding system of the mobile robot comprises a welding gun head, a welding gun barrel, a wire drawing device, guide wheels, a tension spring, a support frame, a wire feeding pipe, a water-cooled cable, guide rods, a straightener, a wire feeding disc, a wire feeding machine, a TIG power supply, a wire feeding support, mobile universal wheels, a robot base, a first robot shaft, a second robot shaft, a third robot shaft, a fourth robot shaft, a fifth robot shaft, a sixth robot shaft, a tungsten electrode, a clamping piece and a high-temperature camera, wherein the TIG power supply is connected with the guide rods through the water-cooled cable, the two guide rods are arranged at the top end of the wire feeding support, the two mobile universal wheels are arranged at the bottom end of the wire feeding support, the straightener, the wire feeding disc and the wire feeding machine are all connected with the wire feeding support, the wire feeding disc is connected with the straightener through the wire feeding pipe, the wire feeding disc is connected with the wire feeding machine through the wire feeding pipe, the wire feeding machine is connected with the guide wheels through the wire feeding pipe, the guide rod is connected with the guide wheel through a water-cooled cable, the wire feeding pipe is positioned below the water-cooled cable, the guide wheel is connected with the support frame through a tension spring, the guide wheel is connected with the wire drawing device through the wire feeding pipe, the wire drawing device is connected with the welding gun barrel, the welding gun barrel is connected with the tungsten electrode, the high-temperature camera is arranged on the welding gun barrel, the wire drawing device is connected with the clamping piece, the clamping piece is connected with the sixth robot shaft, the sixth robot shaft is connected with the fifth robot shaft, the fifth robot shaft is connected with the fourth robot shaft, the fourth robot shaft is connected with the third robot shaft, the third robot shaft is connected with the second robot shaft, the support frame is arranged on the third robot shaft, the second robot shaft is connected with the first robot shaft, the first robot shaft is connected with the robot base, and the robot base is positioned on the right side of the wire feeding support, the wire feeding bracket is positioned on the right side of the TIG power supply;
the heat treatment system comprises a medium-frequency induction internal heating power supply, a medium-frequency induction external heating power supply, a first water-cooling heating power supply, a second water-cooling heating power supply, an air-cooled cable, a heat treatment lifting device, heat-insulating cotton, a valve body and an induction coil, wherein the heat treatment lifting device comprises a first stepping motor, a sliding table, an L-shaped coil fixing flange plate, a valve cover end surface, a horizontal moving fixing steel plate, a screw rod fixing nut, a sliding table positioning block, a device fixing screw hole, a hand wheel, a moving screw rod, a supporting piece and a fixing steel plate, the induction coil comprises high silica cloth, a disc-shaped coil, a mica plate fixing bolt, an insulating flange plate, a water-cooling copper pipe and a cross frame, the medium-frequency induction internal heating power supply is positioned on the right side of the first water-cooling heating power supply, the medium-frequency induction external heating power supply is positioned below the medium-frequency induction internal heating power supply, the first water-cooling heating power supply is connected with the second water-cooling heating power supply through a medium-frequency induction internal heating power supply, the second water-cooling heating power supply is positioned below the first water-cooling heating power supply, an air-cooling cable is connected with a medium-frequency induction external heating power supply, the heat treatment lifting device is positioned on the left side of the first water-cooling heating power supply, the heat insulation cotton is positioned below the heat treatment lifting device, the valve body is positioned on the left side of the induction coil, the induction coil is positioned below the second water-cooling heating power supply, the first stepping motor is connected with the sliding table positioning block through a sliding table, the sliding table is positioned at the bottom of the first stepping motor, the L-shaped coil fixing flange plate is positioned on the right side of the sliding table, the valve cover end surface is positioned at the bottom of the sliding table, the horizontal moving fixing steel plate is positioned above the moving screw rod, the screw rod fixing nut is connected with the hand wheel through the moving screw rod, the sliding table positioning block is positioned below the screw rod fixing nut, and the device fixing screw hole is positioned on the right side of the supporting piece, the hand wheel is positioned on the right side of the movable screw rod, the movable screw rod is positioned on the right side of the screw rod fixing nut, the supporting piece is positioned above the movable screw rod, the fixing steel plate is positioned on the left side of the first stepping motor, the high silica cloth is positioned on the top of the left side of the mica plate, the disc-shaped coil is positioned at the bottom of the high silica cloth, the mica plate and the insulating flange cover are connected through a water-cooling copper pipe, the mica plate fixing bolt is positioned above the water-cooling copper pipe, the insulating flange plate is positioned on the right side of the water-cooling copper pipe, the water-cooling copper pipe is positioned on the right side of the mica plate, and the cross is positioned at the top of the high silica cloth;
digital display grinder includes the second step motor, the riser, lift platform, first fixing bolt, the main shaft, the abrasive disc, the turbine case, grinding motor, the support upper plate, the camera, the support hypoplastron, the valve body, the surfacing layer, tight device rises, the second step motor links to each other with the riser, lift platform, the support upper plate all links to each other with the riser, lift platform is located the top of support upper plate, lift platform links to each other with the turbine case, the turbine case links to each other with grinding motor, a plurality of cameras are installed on the support upper plate, the support upper plate passes through the main shaft and links to each other with the abrasive disc, the abrasive disc links to each other with tight device that rises, tight device links to each other with the surfacing layer, the surfacing layer is installed on the valve body, the valve body links to each other with the support hypoplastron through a plurality of first fixing bolt, the support hypoplastron links to each other with the support upper plate through the main shaft.
Preferably, the tensioning device comprises a ratchet wheel, a ball, a tensioning block, a positioning ring, a grinding shaft, a tensioning device upper plate, a tensioning device lower plate, a spring, a positioning pin, a ball positioning pin and a rubber ring, wherein the plurality of ratchet wheels, the plurality of balls and the plurality of tensioning blocks are all installed on the positioning ring, the plurality of ratchet wheels and the balls are connected with the tensioning block, the ratchet wheel is located outside the ball, the positioning ring is connected with the tensioning device lower plate, the tensioning device lower plate is connected with the plurality of positioning pins, the spring is connected with the positioning pin, the positioning pin is located on one side of the rubber ring, the rubber ring is connected with the tensioning device lower plate, the tensioning device upper plate is connected with the tensioning device lower plate through the plurality of ball positioning pins, the grinding shaft sequentially penetrates through the tensioning device upper plate, and the tensioning device lower plate is connected with the positioning ring.
Preferably, the bracket lower plate comprises a second fixing bolt, an upper end face of the valve body and a central positioning plate, and the central positioning plate is connected with the upper end face of the valve body through a plurality of second fixing bolts.
Preferably, the grinding disc comprises a positioning plate mounting hole, a grinding disc body and a positioning plate, wherein the positioning plate mounting hole and the grinding disc mounting hole are both mounted on the grinding disc body, the positioning plate mounting hole is located on the outer ring of the grinding disc mounting hole, and the grinding disc body is connected with the positioning plate.
The positive progress effects of the invention are as follows: in the aspect of a repair scheme, a return-to-factory maintenance scheme for destructive separation and disassembly or cleaning of the valve, which is mostly adopted by domestic manufacturers at present, is avoided, and the sealing surface is maintained on the working site of the valve; in the aspect of repairing equipment, the traditional special repairing equipment with one valve and one equipment is avoided, and a robot with more flexibility and intellectualization is adopted to realize automatic repairing; the repair result can completely meet the initial requirements of design and manufacture, and the hardness, the wear resistance and the high-temperature performance of the repaired sealing surface are all equivalent to or higher than those of the original design; the timeliness of on-site repair is solved, the designed equipment can quickly finish on-site positioning and installation, and the construction process can be quickly finished in the valve cavity; the problem of synergy of welding and heat treatment in the valve cavity is solved; the method has the characteristics of excellent quality after repair, high repair efficiency, low cost of the whole repair and good economy.
Drawings
Fig. 1 is a schematic diagram of an online repair system for a sealing surface of a high-temperature and high-pressure steam valve.
Fig. 2 is a schematic structural diagram of a mobile robot TIG welding system.
FIG. 3 is a schematic view of a thermal processing system.
Fig. 4 is a cross-sectional view of a thermal processing system.
Fig. 5 is a diagram of an induction coil of the thermal processing system.
Fig. 6 is a left side view of the induction coil.
Fig. 7 is a schematic structural view of the heat treatment lifting device.
Fig. 8 is a left side view of the heat treatment elevating device.
Fig. 9 is a rear view of the heat treatment elevating device.
FIG. 10 is a schematic view of a digital display polishing apparatus.
Fig. 11 is a schematic structural view of the tensioning device of the present invention.
Fig. 12 is a bottom view of the tensioning device of the invention.
Fig. 13 is a schematic structural view of a lower plate of the bracket of the present invention.
FIG. 14 is a top view of an abrasive disk of the present invention.
FIG. 15 is a schematic view of the structure of the polishing disk of the present invention.
Detailed Description
The following provides a detailed description of the preferred embodiments of the present invention with reference to the accompanying drawings.
As shown in fig. 1 to 13, the high-temperature and high-pressure steam valve sealing surface on-line repairing system of the present invention includes a mobile robot TIG (non-consumable inert gas tungsten arc welding) welding system, a heat treatment system, and a digital display grinding device which are connected with each other;
the TIG welding system of the mobile robot comprises a welding gun head 1, a welding gun barrel 2, a wire drawing device 3, a guide wheel 4, a tension spring 5, a support frame 6, a wire feeding pipe 7, a water-cooled cable 8, a guide rod 9, a straightening device 10, a wire feeding disc 11, a wire feeding machine 12, a TIG power supply 13, a wire feeding support 14, a mobile universal wheel 15, a robot base 16, a first robot shaft 17, a second robot shaft 18, a third robot shaft 19, a fourth robot shaft 20, a fifth robot shaft 21, a sixth robot shaft 22, a tungsten electrode 23, a clamping piece 24 and a high-temperature camera 25, wherein the TIG power supply 13 is connected with the guide rod 9 through the water-cooled cable 8, the two guide rods 9 are arranged at the top end of the wire feeding support 14, the two mobile universal wheels 15 are arranged at the bottom end of the wire feeding support 14, the straightening device 10, the wire feeding disc 11 and the wire feeding machine 12 are connected with the support 14, the wire feeding disc 11 is connected with the straightening device 10 through the wire feeding pipe 7, the wire feeding disc 11 is connected with a wire feeding machine 12 through a wire feeding pipe 7, the wire feeding machine 12 is connected with a guide wheel 4 through the wire feeding pipe 7, a guide rod 9 is connected with the guide wheel 4 through a water-cooled cable 8, the wire feeding pipe 7 is positioned below the water-cooled cable 8, the guide wheel 4 is connected with a support frame 6 through a tension spring 5, the guide wheel 4 is connected with a wire drawing machine 3 through the wire feeding pipe 7, the guide wheel 4 is connected with the wire drawing machine 3 through the water-cooled cable 8, the wire drawing machine 3 is connected with a welding gun barrel 2, the welding gun barrel 2 is connected with a welding gun head 1, the welding gun head 1 is connected with a tungsten electrode 23, a high-temperature camera 25 is arranged on the welding gun barrel 2, the wire drawing machine 3 is connected with a clamping piece 24, the clamping piece 24 is connected with a sixth robot shaft 22, the sixth robot shaft 22 is connected with a fifth robot shaft 21, the fifth robot shaft 21 is connected with a fourth robot shaft 20, and the fourth robot shaft 20 is connected with a third robot shaft 19, the third robot shaft 19 is connected with the second robot shaft 18, the support frame 6 is installed on the third robot shaft 19, the second robot shaft 18 is connected with the first robot shaft 17, the first robot shaft 17 is connected with the robot base 16, the robot base 16 is located on the right side of the wire feeding support 14, and the wire feeding support 14 is located on the right side of the TIG power supply 13.
The heat treatment system comprises a medium-frequency induction internal heating power supply 21, a medium-frequency induction external heating power supply 22, a first water-cooling heating power supply 23, a second water-cooling heating power supply 24, an air-cooled cable 25, a heat treatment lifting device 26, heat insulation cotton 27, a valve body 28 and an induction coil 29, wherein the heat treatment lifting device 26 comprises a first stepping motor 30, a sliding table 31, an L-shaped coil fixing flange plate 32, a valve cover end surface 33, a horizontal moving fixing steel plate 34, a lead screw fixing nut 35, a sliding table positioning block 36, a device fixing screw hole 37, a hand wheel 38, a moving lead screw 39, a supporting piece 40 and a fixing steel plate 41, the induction coil 29 comprises high silica cloth 42, a disc-shaped coil 43, a mica plate 44, a mica plate fixing bolt 45, an insulating flange plate 46, a water-cooling copper pipe 47 and a cross 48, the medium-frequency induction internal heating power supply 21 is positioned on the right side of the first water-cooling heating power supply 23, the medium-frequency induction external heating power supply 22 is positioned below the medium-frequency induction internal heating power supply 1, the first water-cooling heating power supply 23 is connected with the second water-cooling heating power supply 24 through the medium-frequency induction internal heating power supply 21, the second water-cooling heating power supply 24 is positioned below the first water-cooling heating power supply 3, the air-cooled cable 25 is connected with the medium-frequency induction external heating power supply 22, the heat treatment lifting device 26 is positioned on the left side of the first water-cooling heating power supply 3, the heat insulation cotton 27 is positioned below the heat treatment lifting device 26, the valve body 28 is positioned on the left side of the induction coil 29, the induction coil 29 is positioned below the second water-cooling heating power supply 24, the first stepping motor 30 is connected with the sliding table positioning block 36 through the sliding table 31, the sliding table 31 is positioned at the bottom of the first stepping motor 30, the L-shaped coil fixing flange 32 is positioned on the right side of the sliding table 31, the valve cover 33 is positioned at the bottom of the sliding table 11, the horizontally-moving fixing steel plate 34 is positioned above the moving screw rod 39, lead screw fixation nut 35 and hand wheel 38 are connected through removing lead screw 39, slip table locating piece 36 is located the below of lead screw fixation nut 35, device fixed screw 37 is located support piece 40's right side, hand wheel 38 is located the right side of removing lead screw 39, it is located the right side of lead screw fixation nut 35 to remove lead screw 39, support piece 40 is located the top of removing lead screw 39, fixed steel plate 41 is located the left side of first step motor 30, silica cloth 42 is located the left top of mica plate 44, disc coil 43 is located the bottom of silica cloth 42, connect through water-cooling copper pipe 47 between mica plate 44 and the insulating flange lid 46, mica plate fixing bolt 45 is located the top of water-cooling copper pipe 47, insulating flange 46 is located the right side of water-cooling copper pipe 47, water-cooling copper pipe 47 is located the right side of mica plate 44, cross 48 is located the top of silica cloth 42.
The digital display grinding device comprises a second stepping motor 51, a lifter 52, a lifting platform 53, a first fixing bolt 54, a main shaft 55, a grinding disc 56, a turbine box 57, a grinding motor 58, a support upper plate 59, cameras 60, a support lower plate 61, a valve body 62, a surfacing layer 63 and a tensioning device 64, wherein the second stepping motor 51 is connected with the lifter 52, the lifting platform 53 and the support upper plate 59 are both connected with the lifter 52, the lifting platform 53 is positioned above the support upper plate 59, the lifting platform 53 is connected with the turbine box 57, the turbine box 57 is connected with the grinding motor 58, the cameras 60 are mounted on the support upper plate 59, the support upper plate 59 is connected with the grinding disc 56 through the main shaft 55, the grinding disc 56 is connected with the tensioning device 64, the tensioning device 64 is connected with the surfacing layer 63, the surfacing layer 63 is mounted on the valve body 62, the valve body 62 is connected with the support lower plate 61 through the first fixing bolts 54, and the support 61 is connected with the support upper plate 59 through the main shaft 55.
The tensioning device 64 comprises ratchet wheels 65, balls 66, a tensioning block 67, a positioning ring 68, a grinding shaft 69, a tensioning device upper plate 70, a tensioning device lower plate 71, a spring 72, a positioning pin 73, a ball positioning pin 74 and a rubber ring 75, wherein the plurality of ratchet wheels 65, the plurality of balls 66 and the plurality of tensioning blocks 67 are all mounted on the positioning ring 68, the plurality of ratchet wheels 65 and the balls 66 are connected with the tensioning block 67, the ratchet wheels 65 are located on the outer sides of the balls 66, the positioning ring 68 is connected with the tensioning device lower plate 71, the tensioning device lower plate 71 is connected with the plurality of positioning pins 73, the spring 72 is connected with the positioning pin 73, the positioning pin 73 is located on one side of the rubber ring 75, the rubber ring 75 is connected with the tensioning device lower plate 71, the tensioning device upper plate 70 is connected with the tensioning device lower plate 71 through the plurality of ball positioning pins 74, and the grinding shaft 69 sequentially penetrates through the tensioning device upper plate 70, the tensioning device lower plate 71 and the positioning ring 68, so that accuracy can be improved.
The support lower plate 61 includes a second fixing bolt 76, a valve body upper end surface 77, and a center positioning plate 78, and the center positioning plate 78 is connected to the valve body upper end surface 77 through a plurality of second fixing bolts 76, so that stability can be improved.
Grinding disk 56 includes locating plate mounting hole 79, grinding disk mounting hole 80, grinding disk body 81, locating plate 82, and locating plate mounting hole 79, grinding disk mounting hole 80 all install on grinding disk body 81, and locating plate mounting hole 79 is located the outer lane of grinding disk mounting hole 80, and grinding disk body 81 links to each other with locating plate 82, can satisfy the removal of grinding residue like this and clear away.
The mobile robotic TIG welding system selects different models of robots, welding equipment, and process parameters depending on the configuration, shape, and size of the repaired device and the installation and operating environment of the field device. When the diameter of the sealing surface of the equipment to be repaired is less than 300mm or the depth is less than 700mm, a small robot with a large load (not less than 7 Kg) is selected, and on the contrary, a medium robot with a large load (not less than 15 Kg) is selected. The welding process parameters are selected based on the location, configuration and size of the different on-site valve seal faces. When the TIG welding system of the mobile robot works, firstly collecting welding voltage under a stable arc length, simultaneously taking the voltage as reference calculation voltage during height tracking, and if the voltage obtained by actual collection deviates from the reference voltage, adjusting the Z-direction height of a TIG welding gun formed by a gun barrel of the welding gun and the gun head of the welding gun; in practical application, two wire feeders are adopted and respectively loaded with nickel-based alloy welding wires and cobalt-based alloy welding wires, the two welding wires are respectively sent out along two sides of a tungsten electrode through wire guide pipes, the type and the wire feeding speed of the specific working wire feeder are determined by a robot consisting of a robot base, a first robot shaft, a second robot shaft, a third robot shaft, a fourth robot shaft, a fifth robot shaft and a sixth robot shaft, and the selection of the wire feeders and the corresponding wire feeding speed are set before a welding instruction in practical use; the robot drives the TIG welding gun to complete a welding task, meanwhile, the robot is used as a central processing unit to process start, stop and logic of signals, the six-axis linkage load is not less than 20Kg (kilogram), the arm length is not less than 1.65m (meter), the Protection level is not lower than IPR (Ingress Protection Rating, protection safety level) 67, the robot can be installed at any angle, has an arc voltage tracking function, the repeated positioning precision (RP) is not more than 0.04mm (millimeter), has the function of arc voltage tracking, timely adjusts the arc height according to the monitored arc voltage, and ensures the forming and quality of the TIG welding gun during welding; the TIG power supply can have different control modes, has the function of controlling two wire feeders, and has the function of realizing digital communication with the robot; the straightener obtains the current through a Hall current sensor, and the specific implementation method is that a ground wire cable penetrates through the Hall current sensor to obtain the current; for voltage output when the TIG power supply is welded by collecting voltage through Hall voltage, in order to avoid influence of high-frequency signal output on collected signals, a grounding wire of a positive end of a Hall current sensor is connected to an output end of a manual welding gun of a negative end of the Hall current sensor; the wire feeder comprises two independent wire feeding mechanisms, a straightener is arranged behind a wire feeding disc, a wire drawing device is additionally arranged at the front end of a TIG welding gun to ensure that the TIG welding gun does not block wires when rotating, a wire pushing device and the wire drawing device work together when welding, the speed of the wire drawing device is slightly greater than the wire pushing and feeding speed (about 5%), a robot can select the wire feeder needing to work through a wire feeder switching control position, and the start and stop of the wire feeder are controlled at the same time; in the actual welding process, one wire feeder realizes nickel-based welding wire filling, and the other wire feeder realizes cobalt-based welding wire filling; the wire feeding bracket is used for carrying the wire feeder, the wire feeding disc and the straightener; the water-cooled cable and the wire feeding pipe are fixed on a guide wheel of the robot, and the guide wheel has the function of guiding the directions of the wire feeding pipe and the water-cooled cable, so that the TIG welding gun can still feed wires smoothly when acting on a clamping piece of the robot according to any posture of 360 degrees; the current adjusting range of the TIG power supply is 5-200A (amperes), the minimum adjustable interval is not more than 1A, and one end of the TIG power supply is connected with a TIG welding gun, so that the deposition efficiency of the cobalt-base alloy welding wire is increased, and the welding speed is increased; the welding gun head is used for welding, the welding gun barrel is used for being connected with the welding gun head, so that the height is conveniently adjusted, the tension spring plays a stretching role, the support frame and the wire feeding support play a supporting role, the movable universal wheel is used for moving the wire feeding support, the tungsten electrode plays a protecting role, the clamping piece plays a supporting role, the high-temperature camera is used for shooting, the interference of arc light is prevented, the process requirement of switching a plurality of layers of welding wires can be met, the arc striking success rate is one hundred percent when automatic welding is carried out, the strict consistency of the arc length when TIG welding is carried out, the heat input change and the wire feeding change caused by the arc length change are prevented, the manufacturing requirement of the sealing surface of the high-temperature high-pressure steam valve can be met, and the part with defects can be directly subjected to surfacing and repairing on the overhaul site of the installed equipment; the invention can flexibly switch the type and speed of wire feeding according to the actual process requirements on site, and meet the requirements of full-position deep pit surfacing welding and composite additive manufacturing of the sealing surface in the high-temperature high-pressure steam valve; the invention can switch the type and quantity of the filling metal in the TIG welding gun welding process at any time without replacing the wire disc on the spot.
The heat treatment system is mainly used for preheating and heat treatment before and after welding of the valve sealing surface, and the heating mode (internal and external), the heating power supply power (30-80 KW), the coil size, the cooling mode (water cooling or air cooling), the heat treatment process and the like are also selected according to the type of a workpiece. When heat treatment is needed, firstly, a tool is fixed on a valve cover by using a valve end cover bolt, then a heating coil is fixed on an L-shaped moving disc, a water-cooling cable for connecting a heating power supply and an induction coil is well connected, before welding or repairing, the induction coil is firstly moved to a valve cover flange opening of a valve body through a lifting table tool, then enters a valve cavity until reaching the inner hole position of a sealing surface, and for the heat treatment of the outer wall, the heating cable mainly comprises a control system, a 60KW medium-frequency induction heating power supply and a flexible air-cooling external heating cable, can be directly wound on the outer wall of an irregular valve body, is in a working state from the beginning preheating of the valve to the finishing of the whole welding, forms a 'thermal dam' on the outer wall of the valve to prevent excessive heat dissipation so as to ensure the heating effect of the sealing surface, the heat treatment of the inner wall and the outer wall starts to work simultaneously, and only exits from the inner heating coil after the constant preheating temperature, the outer wall heat treatment continues to be at constant temperature to ensure the interlayer temperature in the welding or repairing process, after the welding or repairing is completed, the inner heating coil enters, the flexible air-cooled coil cable of the outer heating power supply and the outer heating coil start to carry out postweld heat treatment at the same heating rate, constant temperature time and cooling rate until the whole heat treatment process is completed completely, in the actual heating process, the flexible air-cooled coil cable of the outer heating power supply is wound outside the welding surface of the valve, the operation of the flexible air-cooled coil cable has five stages, wherein the heating temperature of the flexible air-cooled coil cable when the inner heating is removed ensures that the temperature of the welding surface is not lower than 300-350 ℃ when the welding is carried out, the first stage is a preheating stage of a welding seam area, the heating induction coil in the stage is driven to the position of the repairing surface in the valve body by a lifting table tool, the inner heating and the outer heating in the stage work simultaneously, the heated position is heated and heated at the preset heating rate for heating and preheating, and the second stage is at the constant temperature of the preheating temperature, the method aims to ensure that the temperature of the inner wall and the outer wall of a welding or repairing part is kept consistent, in the third stage, after the preheating temperature is constant, an internal heating induction coil is driven by a lifting table tool to be drawn out of a valve cavity, at the moment, external heating continues to work in the second stage, the temperature of the welding or repairing process is not lower than 300 ℃ until the welding or repairing work is finished, the internal heating and the external heating are carried out in the fourth stage to the fifth stage simultaneously, and the work is heated and cooled according to a set heat treatment curve, so that the requirements of a heat treatment process in the welding or repairing process can be met according to the complexity of the structure and the environment of a sealing surface of a high-temperature and high-pressure steam valve on site. The utility model discloses a valve body, including the slip table locating piece, the internal heating can be started to the internal heating power of intermediate frequency response, the external heating can be started to the intermediate frequency response, first water-cooling heating power can start the water-cooling heating, the water-cooling heating can be started to the second water-cooling heating power, heat treatment elevating gear can reach the effect of going up and down when thermal treatment, the heat preservation cotton can keep warm, step motor provides the electric quantity, the slip table leans on the slip table locating piece, L type coil mounting flange dish is fixed stable, high-usage, horizontal migration mounting plate plays fixed effect, lead screw fixation nut fixes removal lead screw, device fixing screw is fixed with screw cooperation, hand wheel control removes the lead screw, it can rotate to remove the lead screw, support piece plays the effect of support, fixing plate plays fixed effect, high silica cloth parcel is on induction coil, the coil is twined in inside, the mica board plays closed effect, mica board fixing bolt plays fixed mica board effect, insulating flange dish convenience is insulating and connection, prevent unexpected emergence, the water-cooling copper pipe can be able to bear the high temperature, the inside of cross fixed induction coil, thus, it is light-type, it is miniaturized, be convenient for on-site installation and operation, avoid because the valve body inclination crack too big sealed face that leads to lead to the sealed face.
The digital display grinding device mainly utilizes concentric circles of a valve cover and a valve seat of a high-temperature high-pressure steam valve, the central points of the valve cover and the valve seat are connected in parallel to form a line, and the requirements of equipment and technology for fine machining of a wear-resistant layer of a sealing surface of field equipment are met by means of a stable tool mechanism, a high-power motor, a high-hardness shaping cutter, a grinding disc and machining real-time monitoring equipment. The system is portable machining equipment, can quickly install a host machine on a fixing device of a valve cover or a flange end face, and is applied to machining of a valve seat of a sealing surface in a valve cavity with a certain depth (not less than 500 mm). The sizing cutting equipment is used for removing the original defective sealing surface and the surplus after re-overlaying, and finally, the grinding equipment is used for obtaining the optimal sealing surface precision (< 0.4 mu m).
For an industrial robot, a six-axis linkage robot system is preferably adopted, and the flexibility of production motion is higher.
For the welding task, the horizontal welding is preferably performed by a MIG welding method, and the all-position welding is preferably performed by a TIG welding method, so that the welding is firmer.
For the heat treatment equipment, a medium-frequency induction heating method is preferably adopted, and the heat treatment equipment is convenient and quick.
For machining equipment, a fixed milling cutter and a grinding disc are preferably adopted, the equipment is universal and low in price.
The invention avoids the return-to-factory maintenance scheme which is mostly adopted by domestic manufacturers at present and is used for destructively separating and disassembling or cleaning the valve in the aspect of the repair scheme, and the sealing surface is maintained on the working site of the valve; in the aspect of repairing equipment, the traditional special repairing equipment with one valve and one equipment is avoided, and a robot with more flexibility and intellectualization is adopted to realize automatic repairing; the problem that the repairing result can completely meet the initial requirements of design and manufacture is solved, and the hardness, the wear resistance and the high-temperature performance of the repaired sealing surface are equivalent to or higher than those of the original design; the timeliness of on-site repair is solved, the designed equipment can quickly finish on-site positioning and installation, and the construction process can be quickly finished in the valve cavity; solves the problem of cooperation of welding and heat treatment in the valve cavity.
In conclusion, the method has the characteristics of excellent quality after repair, high repair efficiency, low cost of the whole repair and good economy.
The above embodiments are described in further detail to solve the technical problems, technical solutions and advantages of the present invention, and it should be understood that the above embodiments are only examples of the present invention and are not intended to limit the present invention, and any modifications, equivalent substitutions, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (4)
1. The online repair system for the sealing surface of the high-temperature and high-pressure steam valve is characterized by comprising a mobile robot TIG welding system, a heat treatment system and a digital display grinding device which are connected with each other;
the TIG welding system of the mobile robot comprises a welding gun head, a welding gun barrel, a wire drawing device, guide wheels, a tension spring, a support frame, a wire feeding pipe, a water-cooled cable, guide rods, a straightener, a wire feeding disc, a wire feeding machine, a TIG power supply, a wire feeding support, mobile universal wheels, a robot base, a first robot shaft, a second robot shaft, a third robot shaft, a fourth robot shaft, a fifth robot shaft, a sixth robot shaft, a tungsten electrode, a clamping piece and a high-temperature camera, wherein the TIG power supply is connected with the guide rods through the water-cooled cable, the two guide rods are arranged at the top end of the wire feeding support, the two mobile universal wheels are arranged at the bottom end of the wire feeding support, the straightener, the wire feeding disc and the wire feeding machine are all connected with the wire feeding support, the wire feeding disc is connected with the straightener through the wire feeding pipe, the wire feeding disc is connected with the wire feeding machine through the wire feeding pipe, the wire feeding machine is connected with the guide wheels through the wire feeding pipe, the guide rod is connected with the guide wheel through a water-cooled cable, the wire feeding pipe is positioned below the water-cooled cable, the guide wheel is connected with the support frame through a tension spring, the guide wheel is connected with the wire drawing device through the wire feeding pipe, the wire drawing device is connected with the welding gun barrel, the welding gun barrel is connected with the tungsten electrode, the high-temperature camera is arranged on the welding gun barrel, the wire drawing device is connected with the clamping piece, the clamping piece is connected with the sixth robot shaft, the sixth robot shaft is connected with the fifth robot shaft, the fifth robot shaft is connected with the fourth robot shaft, the fourth robot shaft is connected with the third robot shaft, the third robot shaft is connected with the second robot shaft, the support frame is arranged on the third robot shaft, the second robot shaft is connected with the first robot shaft, the first robot shaft is connected with the robot base, and the robot base is positioned on the right side of the wire feeding support, the wire feeding bracket is positioned on the right side of the TIG power supply;
the current regulation range of a TIG power supply is 5 to 200A, and one end of the TIG power supply is connected with a gun barrel of a welding gun of a TIG welding system;
the heat treatment system comprises a medium-frequency induction internal heating power supply, a medium-frequency induction external heating power supply, a first water-cooling heating power supply, a second water-cooling heating power supply, an air-cooled cable, a heat treatment lifting device, heat-insulating cotton, a valve body and an induction coil, wherein the heat treatment lifting device comprises a first stepping motor, a sliding table, an L-shaped coil fixing flange plate, a valve cover end surface, a horizontal moving fixing steel plate, a screw rod fixing nut, a sliding table positioning block, a device fixing screw hole, a hand wheel, a moving screw rod, a supporting piece and a fixing steel plate, the induction coil comprises high silica cloth, a disc-shaped coil, a mica plate fixing bolt, an insulating flange plate, a water-cooling copper pipe and a cross frame, the medium-frequency induction internal heating power supply is positioned on the right side of the first water-cooling heating power supply, the medium-frequency induction external heating power supply is positioned below the medium-frequency induction internal heating power supply, the first water-cooling heating power supply is connected with the second water-cooling heating power supply through a medium-frequency induction internal heating power supply, the second water-cooling heating power supply is positioned below the first water-cooling heating power supply, an air-cooling cable is connected with a medium-frequency induction external heating power supply, the heat treatment lifting device is positioned on the left side of the first water-cooling heating power supply, the heat insulation cotton is positioned below the heat treatment lifting device, the valve body is positioned on the left side of the induction coil, the induction coil is positioned below the second water-cooling heating power supply, the first stepping motor is connected with the sliding table positioning block through the sliding table, the sliding table is positioned at the bottom of the first stepping motor, the L-shaped coil fixing flange plate is positioned on the right side of the sliding table, the valve cover end surface is positioned at the bottom of the sliding table, the horizontally moving fixing steel plate is positioned above the moving screw rod, the screw rod fixing nut is connected with the hand wheel through the moving screw rod, the sliding table positioning block is positioned below the screw rod fixing nut, and the device fixing screw hole is positioned on the right side of the supporting piece, the hand wheel is positioned on the right side of the movable screw rod, the movable screw rod is positioned on the right side of the screw rod fixing nut, the supporting piece is positioned above the movable screw rod, the fixing steel plate is positioned on the left side of the first stepping motor, the high silica cloth is positioned on the top of the left side of the mica plate, the disc-shaped coil is positioned at the bottom of the high silica cloth, the mica plate and the insulating flange cover are connected through a water-cooling copper pipe, the mica plate fixing bolt is positioned above the water-cooling copper pipe, the insulating flange plate is positioned on the right side of the water-cooling copper pipe, the water-cooling copper pipe is positioned on the right side of the mica plate, and the cross is positioned at the top of the high silica cloth;
the digital display grinding device comprises a second stepping motor, a lifter, a lifting platform, first fixing bolts, a main shaft, a grinding disc, a turbine box, a grinding motor, a support upper plate, a camera, a support lower plate, a valve body, a surfacing layer, a tensioning device, the second stepping motor is connected with the lifter, the lifting platform, the support upper plate is connected with the lifter, the lifting platform is positioned above the support upper plate, the lifting platform is connected with the turbine box, the turbine box is connected with the grinding motor, a plurality of cameras are installed on the support upper plate, the support upper plate is connected with the grinding disc through the main shaft, the grinding disc is connected with the tensioning device, the tensioning device is connected with the surfacing layer, the surfacing layer is installed on the valve body, the valve body is connected with the support lower plate through a plurality of first fixing bolts, and the support lower plate is connected with the support upper plate through the main shaft.
2. The system for repairing a sealing surface of a high-temperature and high-pressure steam valve online as claimed in claim 1, wherein the tensioning device comprises a ratchet wheel, balls, a tensioning block, a positioning ring, a grinding shaft, an upper plate of the tensioning device, a lower plate of the tensioning device, a spring, a positioning pin, a ball positioning pin and a rubber ring, the ratchet wheels, the balls and the tensioning block are all mounted on the positioning ring, the ratchet wheels and the balls are connected with the tensioning block, the ratchet wheels are located on the outer sides of the balls, the positioning ring is connected with the lower plate of the tensioning device, the lower plate of the tensioning device is connected with the positioning pins, the spring is connected with the positioning pin, the positioning pin is located on one side of the rubber ring, the rubber ring is connected with the lower plate of the tensioning device, the upper plate of the tensioning device is connected with the lower plate of the tensioning device through the ball positioning pins, the grinding shaft sequentially penetrates through the upper plate of the tensioning device and the lower plate of the tensioning device is connected with the positioning ring.
3. The system for repairing a sealing surface of a high-temperature and high-pressure steam valve online as recited in claim 2, wherein the lower plate of the bracket comprises second fixing bolts, an upper end surface of the valve body, and a center positioning plate, and the center positioning plate is connected with the upper end surface of the valve body through a plurality of second fixing bolts.
4. The high-temperature high-pressure steam valve sealing surface on-line repairing system of claim 3, wherein the grinding disc comprises a positioning plate mounting hole, a grinding disc body and a positioning plate, the positioning plate mounting hole and the grinding disc mounting hole are both mounted on the grinding disc body, the positioning plate mounting hole is located on the outer ring of the grinding disc mounting hole, and the grinding disc body is connected with the positioning plate.
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| CN201710289352.7A CN107030446B (en) | 2017-04-27 | 2017-04-27 | Online repair system for sealing surface of high-temperature and high-pressure steam valve |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107457470A (en) * | 2017-09-21 | 2017-12-12 | 济南时代新纪元科技有限公司 | One kind welding increasing material manufacturing robot |
| CN109986280A (en) * | 2017-12-29 | 2019-07-09 | 核动力运行研究所 | A kind of equipment repaired online suitable for main pump flange sealing surface |
| CN108489673B (en) * | 2018-04-28 | 2023-11-03 | 苏州纽威阀门股份有限公司 | Measuring device for sealing surface of three-eccentric butterfly valve and measuring method for tightness |
| CN110052777B (en) * | 2018-09-30 | 2020-03-20 | 上海吴泾电力工程有限责任公司 | On-site repairing method suitable for pit cavity space |
| CN113634953A (en) * | 2021-08-25 | 2021-11-12 | 无锡市福莱达石油机械有限公司 | Preheating and heat preservation method for valve seat |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN2066789U (en) * | 1989-07-01 | 1990-12-05 | 中国石油化工总公司金陵石油化工公司化肥厂 | On-line repairing device for high-pressure valve sealing surface |
| US7854254B2 (en) * | 2005-10-03 | 2010-12-21 | Taper-Lok Corporation | Systems and methods for making seals in heat exchangers |
| DE102009046401B4 (en) * | 2009-11-04 | 2012-08-09 | Areva Np Gmbh | Method and device for processing a sealing seat of a shut-off valve |
| CN102689085B (en) * | 2012-06-07 | 2014-12-10 | 中国东方电气集团有限公司 | Autonomous mobile dithering hot wire tungsten-inert-gas (TIG) welding robot system for welding large-sized precision equipment |
| CN102756235B (en) * | 2012-07-23 | 2014-07-23 | 苏州热工研究院有限公司 | Field welding repair method especially for larger and penetrating defects in steel casting with heavy wall thickness |
| US9103447B1 (en) * | 2014-02-13 | 2015-08-11 | Hager Industries, LLC | Method and system of valve refurbishment |
| CN204887507U (en) * | 2015-07-08 | 2015-12-16 | 昆山倚天自动化有限公司 | A buckle tip intermediate frequency heating equipment for on hasp assembly line |
| CN206925519U (en) * | 2017-04-27 | 2018-01-26 | 上海电力股份有限公司吴泾热电厂 | The online repair system of steam valve sealing surface |
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