CN110814475A - Welding workload calculation method - Google Patents
Welding workload calculation method Download PDFInfo
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- CN110814475A CN110814475A CN201911239785.7A CN201911239785A CN110814475A CN 110814475 A CN110814475 A CN 110814475A CN 201911239785 A CN201911239785 A CN 201911239785A CN 110814475 A CN110814475 A CN 110814475A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
- B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
- B23K35/0261—Rods, electrodes, wires
- B23K35/0266—Rods, electrodes, wires flux-cored
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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Abstract
The invention discloses a welding workload calculation method which is characterized in that identity information of welding seams is determined by numbering each welding seam, the theoretical filling metal amount of each welding seam is calculated to be compared with the welding material consumption per minute of different welding methods measured on site, and meanwhile, the theoretical welding working hour of each welding seam is obtained by considering a welding difficulty coefficient; the method can conveniently calculate the welding time of each welding line by means of an EXCEL table formula and a data function, and has a relatively accurate guiding function on welding material consumption, welding cost, bid price, welding production plan and welding performance assessment.
Description
The technical field is as follows:
the invention relates to the technical field of construction method calculation, in particular to a method for calculating welding workload; the welding material consumption and the welding working hour cost can be accurately calculated, and the method has a relatively accurate guiding function on project bid price, welding production plan and welding performance assessment.
Background art:
at present, welding workload is generally estimated according to experience, data support is lacked, the difference between an estimated value and an actual situation is large, and project bid price, welding production plan and welding performance assessment are lacked, so that the bid price estimation is inaccurate, the production plan is unreasonable, the welding performance is unsatisfactory, and the fine management of enterprises cannot be achieved.
The invention content is as follows:
the present invention is directed to overcome the above problems of the prior art and to provide a method for calculating a welding work amount.
The technical scheme provided by the invention is as follows: a welding work amount calculation method is characterized by comprising the following steps:
a, counting weld joint information: numbering the welding seams, determining welding seam identity information, counting the shapes of welding seam grooves, the lengths of the welding seams, welding process numbers, base metal materials, the thicknesses of base metal plates, welding positions, operating environments and NDT modes to form a welding seam statistical table;
b, calculating the cross section area of the welding seam: drawing all the shapes of the welding seam sections through CAD (computer-aided design) drawing, calculating the welding seam section areas of all the shapes by utilizing a CAD (computer-aided design) area calculation function, recording the welding seam section area data into an EXCEL table to form a database, and calling the data into a welding seam statistical table; the weld cross-sectional area database is shown in table 1:
c, calculating the weight of the weld filler metal: the weight of the weld filler metal = the cross-sectional area of the weld and the length of the weld and rho iron, and substituting a formula into a weld statistical table to automatically generate the weight of the weld filler metal;
d, calculating the weight of the consumed welding materials:
weight of weld consumed weld material = weight of weld filler metal (ρ iron/ρ)/η
Wherein:
ρ iron =7.8g/cm3, ρ = density of the solder material, η = utilization of the solder material,
substituting the formula into a weld statistical table to automatically generate the weight of the weld consumption welding material;
e determining factors influencing welding efficiency: the influence factors include five major categories of base material, base material plate thickness, welding position, operation environment and NDT mode; setting a difficulty coefficient according to the influence factors to form a welding difficulty coefficient table, and calling data into a welding seam statistical table; the weld difficulty coefficients are tabulated in table 2:
f, measuring the weight of the consumed welding materials per minute: measuring the weight of the welding material consumed by each minute in the process specified welding parameter range by various welding methods on site to obtain data, and calling the data into a weld joint statistical table;
g, calculating pure welding working hours: pure welding man-hour = consumed welding material weight difficulty coefficient/consumed welding material weight per minute; pure welding working hours can be automatically generated by substituting the formula into a weld statistical table;
h determining auxiliary man-hours: the welding step is refined into 8 steps of cleaning before welding, cleaning between layers, cleaning a nozzle of a contact tube, shearing the end part of a welding wire, moving, controlling the temperature between layers, changing a welding material and cleaning after welding, and the proportional relation between the auxiliary working hour and the pure welding working hour is determined through simulation actions; the auxiliary working hours of the oxygen welding and the shielded metal arc welding and the pure welding working hours are 4: 4; the submerged arc welding, argon arc welding, STT auxiliary working hours and pure welding working hours are 3: 5; the ratio is called in weld statistical table;
i determining welding man-hour: welding man-hour = pure welding man-hour + auxiliary man-hour, substituting the formula into weld statistical table can automatically generate welding man-hour; weld statistics are shown in table 3:
furthermore, the base material materials are classified into three categories of carbon steel, alloy high-strength steel and stainless steel; the thickness of the base metal plate is divided into four categories of 0-25 mm, 25-38 mm, 38-70 mm and more than 70 mm; the welding positions are divided into five categories of horizontal welding, transverse welding, vertical welding, overhead welding and all-position welding; the working environment is divided into four categories of workshop, open-air ground, high-altitude operation and closed space; the NDT mode is divided into four categories of visual inspection, MT magnetic powder UT ultrasonic wave and RT ray.
The invention has the beneficial effects that: the method can conveniently calculate the welding time of each welding line by means of a CAD drawing function, an EXCEL table formula and a data function, has a relatively accurate guiding function on welding material consumption, welding cost, bid price, welding production plan and welding performance assessment, and improves the fine management level of enterprises.
Description of the drawings:
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a schematic cross-sectional area of a weld of the present invention.
The specific implementation mode is as follows:
for a better understanding and practice, the following detailed description of specific embodiments is given in conjunction with the accompanying drawings.
As shown in fig. 1 and 2; a welding work amount calculation method comprising the steps of:
1. and (3) counting weld joint information: numbering the welding seams, and determining welding seam identity information comprising the welding seam identity information; counting the shape of a welding seam groove, the length of the welding seam, the welding process number, the material quality of a base metal, the thickness of the base metal plate, the welding position, the operation environment and the NDT mode to form a welding seam statistical table;
2. calculating the cross section area of the welding seam: drawing all the shapes of the welding seam sections through CAD (computer-aided design) drawing, calculating the welding seam section areas of all the shapes by utilizing a CAD (computer-aided design) area calculation function, recording the welding seam section area data into an EXCEL table to form a database, and calling the data into a welding seam statistical table; the weld cross-sectional area database is shown in table 1:
3. calculating the weight of the weld filler metal: the weight of the weld filler metal = the cross-sectional area of the weld and the length of the weld and rho iron, and the weight of the weld filler metal can be automatically generated by substituting a formula into a weld statistical table;
4. calculating the weight of the consumed welding materials:
weight of weld consumed weld material = weight of weld filler metal (ρ iron/ρ)/η
Rho iron =7.8g/cm3, rho = density of welding material, η = utilization rate of welding material [ FCAW 90%, SAW 90%, GMAW (CO 2 gas shielded welding) 80%, GTAW (tungsten electrode argon arc welding) 80% ];
the weight of welding materials consumed by the welding line can be automatically generated by substituting the formula into a welding line statistical table;
5. determining factors affecting welding efficiency: the main influencing factors comprise five major categories of base metal materials, base metal plate thickness, welding positions, operation environments and NDT modes, wherein the base metal materials are divided into three categories of carbon steel, alloy high-strength steel and stainless steel; the thickness of the base metal plate is divided into four categories of 0-25 mm, 25-38 mm, 38-70 mm and more than 70 mm; the welding positions are divided into five categories of horizontal welding, transverse welding, vertical welding, overhead welding and all-position welding; the working environment is divided into four categories of workshop, open-air ground, high-altitude operation and closed space; NDT modes are classified into visual inspection, MT magnetic powder UT ultrasonic wave and RT ray; setting a difficulty coefficient according to the influence factors to form a welding difficulty coefficient table, and calling data into a welding seam statistical table; the weld difficulty coefficients are tabulated in table 2:
6. measuring the weight of consumed welding materials per minute: the weight of welding materials consumed per minute within the process specified welding parameter range by various welding methods is measured on site to obtain data, and flux-cored welding (FCAW) consumes 60 grams of flux-cored wire per minute on average; submerged Arc Welding (SAW) consumes an average of 120 grams of welding wire per minute; shielded Metal Arc Welding (SMAW) welding consumes an average of 30 grams of electrode per minute; the average consumption of 10 grams of welding wire per minute in the tungsten argon arc welding (GTAW) welding process; CO2 gas shielded welding (GMAW) consumes an average of 70 grams of wire per minute; the carbon planing speed is measured according to 100 mm/min; data are transferred into weld statistical table;
7. calculating pure welding time: pure welding man-hour = consumed welding material weight difficulty coefficient/consumed welding material weight per minute; pure welding working hours can be automatically generated by substituting the formula into a weld statistical table;
8. determining auxiliary man-hours: the welding step is refined into 8 steps of cleaning before welding, cleaning between layers, cleaning a nozzle of a contact tube, cutting the end part of a welding wire, moving, controlling the temperature between layers, changing a welding material and cleaning after welding, and the proportional relation between the auxiliary working hour and the pure welding working hour is determined through simulation actions, wherein the auxiliary working hour and the pure welding working hour (the oxygen welding and the welding rod arc welding) are 4: 4, (submerged arc welding, argon arc welding, STT) auxiliary man-hours and pure welding man-hours are 3: 5; the ratio is called in weld statistical table;
9. determining welding man-hour: welding man-hour = pure welding man-hour + auxiliary man-hour, substituting the formula into weld statistical table can automatically generate welding man-hour; weld statistics are shown in table 3:
calculating an output result of the data in an EXCEL table through a formula to form a weld joint statistical table; the weld statistical table definitely calculates the filling weight of welding materials of each weld, welding time, and has relatively accurate guiding function on the consumption of the welding materials, the welding cost, the bid price, the welding production plan and the welding performance assessment, and the fine management level of enterprises is improved.
It should be understood that technical features not described in detail in the specification belong to the prior art. The above embodiments are merely illustrative of the preferred embodiments of the present invention, and not restrictive, and various changes and modifications to the technical solutions of the present invention may be made by those skilled in the art without departing from the spirit of the present invention, and the technical solutions of the present invention are intended to fall within the scope of the present invention defined by the appended claims.
Claims (2)
1. A welding work amount calculation method characterized by comprising the steps of:
a, counting weld joint information: numbering the welding seams, determining welding seam identity information, counting the shapes of welding seam grooves, the lengths of the welding seams, welding process numbers, base metal materials, the thicknesses of base metal plates, welding positions, operating environments and NDT modes to form a welding seam statistical table;
b, calculating the cross section area of the welding seam: drawing all the shapes of the welding seam sections through CAD (computer-aided design) drawing, calculating the welding seam section areas of all the shapes by utilizing a CAD (computer-aided design) area calculation function, recording the welding seam section area data into an EXCEL table to form a database, and calling the data into a welding seam statistical table; the weld cross-sectional area database is shown in table 1:
c, calculating the weight of the weld filler metal: the weight of the weld filler metal = the cross-sectional area of the weld and the length of the weld and rho iron, and substituting a formula into a weld statistical table to automatically generate the weight of the weld filler metal;
d, calculating the weight of the consumed welding materials:
weight of weld consumed weld material = weight of weld filler metal (ρ iron/ρ)/η
Wherein:
ρ iron =7.8g/cm3, ρ = density of the solder material, η = utilization of the solder material,
substituting the formula into a weld statistical table to automatically generate the weight of the weld consumption welding material;
e determining factors influencing welding efficiency: the influence factors include five major categories of base material, base material plate thickness, welding position, operation environment and NDT mode; setting a difficulty coefficient according to the influence factors to form a welding difficulty coefficient table, and calling data into a welding seam statistical table; the weld difficulty coefficients are tabulated in table 2:
f, measuring the weight of the consumed welding materials per minute: measuring the weight of the welding material consumed by each minute in the process specified welding parameter range by various welding methods on site to obtain data, and calling the data into a weld joint statistical table;
g, calculating pure welding working hours: pure welding man-hour = consumed welding material weight difficulty coefficient/consumed welding material weight per minute; pure welding working hours can be automatically generated by substituting the formula into a weld statistical table;
h determining auxiliary man-hours: the welding step is refined into 8 steps of cleaning before welding, cleaning between layers, cleaning a nozzle of a contact tube, shearing the end part of a welding wire, moving, controlling the temperature between layers, changing a welding material and cleaning after welding, and the proportional relation between the auxiliary working hour and the pure welding working hour is determined through simulation actions; the auxiliary working hours of the oxygen welding and the shielded metal arc welding and the pure welding working hours are 4: 4; the submerged arc welding, argon arc welding, STT auxiliary working hours and pure welding working hours are 3: 5; the ratio is called in weld statistical table;
i determining welding man-hour: welding man-hour = pure welding man-hour + auxiliary man-hour, substituting the formula into weld statistical table can automatically generate welding man-hour; weld statistics are shown in table 3:
。
2. the method of claim 1, wherein the base material is selected from the group consisting of carbon steel, high-strength alloy steel, and stainless steel; the thickness of the base metal plate is divided into four categories of 0-25 mm, 25-38 mm, 38-70 mm and more than 70 mm; the welding positions are divided into five categories of horizontal welding, transverse welding, vertical welding, overhead welding and all-position welding; the working environment is divided into four categories of workshop, open-air ground, high-altitude operation and closed space; the NDT mode is divided into four categories of visual inspection, MT magnetic powder UT ultrasonic wave and RT ray.
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| CN111639893A (en) * | 2020-05-20 | 2020-09-08 | 上海外高桥造船有限公司 | Method for obtaining consumption coefficient of ship welding material and ship welding material consumption |
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