CN112475538A - Water-cooled wall on-site automatic surfacing device based on self-adaptive principle - Google Patents
Water-cooled wall on-site automatic surfacing device based on self-adaptive principle Download PDFInfo
- Publication number
- CN112475538A CN112475538A CN202011255828.3A CN202011255828A CN112475538A CN 112475538 A CN112475538 A CN 112475538A CN 202011255828 A CN202011255828 A CN 202011255828A CN 112475538 A CN112475538 A CN 112475538A
- Authority
- CN
- China
- Prior art keywords
- welding
- self
- water
- cooled wall
- adaptive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- 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
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
-
- 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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
-
- 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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/127—Means for tracking lines during arc welding or cutting
- B23K9/1272—Geometry oriented, e.g. beam optical trading
- B23K9/1274—Using non-contact, optical means, e.g. laser means
-
- 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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Optics & Photonics (AREA)
- Geometry (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The invention belongs to the technical field of water-cooled wall pipeline repair equipment, and particularly relates to a self-adaptive principle-based water-cooled wall on-site automatic surfacing device. The remote visual automatic surfacing welding for the water-cooled wall is realized, and the high-quality surfacing welding layer is ensured to be obtained by utilizing the arc height self-adaption technology and the walking teaching technology, so that the actual requirement of field welding is met.
Description
Technical Field
The invention belongs to the technical field of water-cooled wall pipeline repairing equipment, and particularly relates to a self-adaptive principle-based on-site automatic surfacing device for a water-cooled wall.
Background
In the field of thermal power stations, a boiler generally adopts a membrane type water-cooled wall structure (the height direction is totally 4 surfaces, the height of a single surface exceeds 50 meters, and the width of the single surface exceeds 30 meters), water in the water-cooled wall is heated by utilizing the combustion of pulverized coal, and a steam turbine is pushed to rotate through generated high-temperature high-pressure steam, so that a generator is pushed to generate electric energy. In the running process of the unit, the surface of the water-cooled wall is affected by high-temperature flue gas corrosion, surface scaling (slagging) and the like, so that the thickness of the water-cooled wall is reduced or the surface of the water-cooled wall is cracked, and pipe explosion occurs in severe cases, so that the unit is abnormally shut down, and the safe running of the unit is seriously affected.
At present, a method for repairing a water-cooled wall pipeline by replacing a pipe is generally adopted, a built scaffold platform or hanging basket is utilized, the pipe is firstly cut, and then the welding of a new pipe and an old pipe is completed in a manual welding mode, so that a large amount of manpower and material resources are consumed, the pipe replacement welding difficulty is large, and the progress is slow; and the butt welding of the common water wall pipeline needs pre-welding preheating and post-welding heat treatment, the operation is complex, the butt joint difficulty is high, and the forming quality is not easy to control.
Disclosure of Invention
In order to solve the technical problems, the invention provides a self-adaptive principle-based on-site automatic water-cooled wall surfacing device, which is a GTAW surfacing device based on a wall-climbing robot, realizes remote visual automatic GTAW surfacing for a water-cooled wall, ensures that a high-quality surfacing layer is obtained by utilizing an arc height self-adaptive technology and a walking teaching technology, meets the actual requirement of on-site welding, avoids the problem of setting up a scaffold or a hanging basket for manual pipe replacement welding, avoids the processes of preheating before welding and heat treatment after welding, shortens the construction period, and reduces the welding repair cost and the technical difficulty.
The invention relates to a self-adaptive principle-based on-site automatic surfacing device for a water-cooled wall, which comprises a three-axis moving platform, a welding torch, an environment camera, a molten pool monitoring camera, an electric arc height self-adaptive module, an arc pressure acquisition module, a wire feeding system, a welding wire position adjusting module and a control system,
the three-axis moving platform is mainly used for integral three-axis movement of the welding head and teaching walking and welding walking of the welding head in the welding process, and comprises a support, a transverse motor, a transverse moving beam, a longitudinal motor, a longitudinal moving beam, an upper motor, a lower motor, an upper moving beam and a lower moving beam, wherein the transverse motor and the transverse moving beam realize transverse movement of the three-axis moving platform; the longitudinal motor and the longitudinal moving beam realize the longitudinal movement of the three-axis moving platform; the up-down motor and the up-down moving beam realize the up-down movement of the three-axis moving platform, a bracket is arranged on the three-axis moving platform, and the whole body is fixed on the wall-climbing robot body through a fixing bolt;
the environment camera is mainly used for observing the whole environment and position; the whole body is fixed on the welding torch through a bolt,
the molten pool monitoring camera is mainly used for observing a welding molten pool in the welding process to ensure the welding forming quality; the whole body is fixed on the welding torch through a bolt,
the welding wire position adjusting module is used for adjusting the relative position between the welding wire and the welding torch, comprises the upper and lower distances, the inner and outer distances and the angle, is integrally fixed on the welding torch through a bolt,
the welding torch is used for actual welding, air is punctured under the action of high-frequency pulses, electric arcs are generated between the tungsten needle and the water-cooled wall, a base metal and a welding wire are melted, welding is completed,
the environment camera, the molten pool monitoring camera, the welding wire position adjusting module and the welding torch are integrally fixed on the arc height self-adapting module through bolts;
the arc height self-adaptive module mainly comprises an adjusting motor, a gear, a rack, an arc voltage acquisition module and an arc height controller, the whole is fixed on an upper moving beam and a lower moving beam of the triaxial moving platform through bolts, the arc height self-adaptive module is mainly used for self-adaptively adjusting the distance between a welding torch (a tungsten needle) and a water-cooled wall in the welding process, the distance between the welding torch and the water-cooled wall is ensured to be kept unchanged according to the numerical value specified by the welding process,
the arc voltage acquisition module is arranged on the outer side of the welding torch and is mainly used for acquiring arc voltage in the welding process, the distance between the welding torch and the water wall is adjusted to a value specified by the welding process by driving the adjusting motor through the arc height controller according to the comparison between the value acquired by the arc voltage acquisition module and a set value,
arc height adaptation principle: during welding, an arc voltage acquisition module arranged outside a welding torch acquires welding voltage in real time, data is transmitted to an arc height controller, the arc height controller drives an adjusting motor to adjust the welding torch upwards or downwards according to the arc height algorithm and the comparison analysis with a set value, so that the distance between the welding torch and a water wall is kept unchanged according to a numerical value specified by a welding process,
arc height algorithm formula: arc voltage is cathode drop + anode drop + arc drop arc height;
the wire feeding system mainly comprises a wire reel, a wire feeding mechanism and a welding wire correcting mechanism, and the whole is fixed on a longitudinal moving beam of the three-axis moving platform through bolts and used for correcting the welding wire and feeding the welding wire.
The walking teaching principle is as follows: in the welding process, in order to ensure that the movement of the welding torch is prevented from deviating according to actual welding requirements, a welding path is planned before welding, and the actual walking path is executed according to teaching by using an x-y two-dimensional coordinate two-point path algorithm and through double-shaft linkage adjustment.
Compared with the prior art, the invention has the following advantages and effects:
1. the on-site automatic surfacing device for the water-cooled wall based on the self-adaptive principle is provided, a scaffold or a hanging basket is not required to be built, the overhaul cost is low, the overhaul period is short, and the safety risk is low;
2. the arc height self-adaptive module realizes the self-adaptive adjustment of the distance between the welding torch and the water wall in the welding process through data acquisition, an algorithm and an execution mechanism, and ensures the welding forming quality; meanwhile, the welding torch and the molten pool are prevented from being adhered, and smooth welding is ensured;
3. the walking teaching function of the welding path reduces the difficulty of welding implementation, can ensure that a surfacing welding seam is arranged according to actual needs, and cannot be missed or repeatedly welded.
Drawings
FIG. 1 is a perspective view of an on-site automatic surfacing device for a water wall based on an adaptive principle according to the present embodiment;
FIG. 2 is a two-dimensional front view of the water-cooled wall on-site automatic surfacing device based on the self-adaptive principle in the embodiment;
FIG. 3 is a two-dimensional left side view of the water-cooled wall on-site automatic surfacing device based on the self-adaptive principle in the embodiment;
FIG. 4 is a two-dimensional top view of the on-site automatic weld deposit device for a water-cooled wall based on the self-adaptive principle in the embodiment;
fig. 5 is a logic diagram of the arc height adaptation principle in the present embodiment.
Wherein, 1-welding torch, 2-environment camera, 3-molten bath monitoring camera, 4-arc height adaptive module, 5-arc voltage collecting module, 6-wire feeding system, 7-welding wire position adjusting module, 8-bracket, 9-transverse motor, 10-transverse moving beam, 11-longitudinal motor, 12-longitudinal moving beam, 13-up-down motor, 14-up-down moving beam, 15-fixing bolt, 16-wall climbing robot, 17-triaxial moving platform, 18-arc voltage collecting module, 19-welding wire reel, 20-wire feeder.
Detailed Description
(1) Testing and installing a wall-climbing robot and a water-cooled wall on-site automatic surfacing device:
based on a wall climbing robot, all parts in the on-site automatic build-up welding device of the water wall are assembled together,
the welding wire position adjusting module is manually adjusted to ensure that the angle, height and offset between the welding wire position and the welding torch meet the requirements of a welding process; the position and the focal length of a monitoring camera of the molten pool are manually adjusted to ensure that the molten pool is clearly observed in the welding process,
and meanwhile, the wall-climbing robot and the whole water-cooled wall on-site automatic surfacing device are subjected to function test, the conditions of the wall-climbing robot and the whole water-cooled wall on-site automatic surfacing device are checked, normal operation is guaranteed, and the three-axis moving platform is adjusted to the highest height so as to prevent the welding head from colliding with the water-cooled wall when the wall-climbing robot walks.
(2) Walking to a specified position:
transfer equipment to water-cooling wall manhole, will climb on-the-spot automatic surfacing welding device of wall robot and water-cooling wall, carry furnace inside respectively, the back that finishes of the equipment adsorbs the robot to the water-cooling wall on to carry the safety rope, prevent that abnormal equipment from falling. The wall-climbing robot is controlled to walk to a position needing welding by observing the camera of the wall-climbing robot and adjusting the remote controller.
(3) Preparing work before welding:
and adjusting the posture of the wall climbing robot to enable the transverse moving beam to be parallel to the length direction of the water wall pipeline. The three-axis mobile platform is adjusted so that the weld path falls within its stroke. The upper motor and the lower motor on the three-axis moving platform are adjusted through the observation environment camera, so that the distance between the welding torch and the water-cooled wall meets the requirements of the welding process.
Determining a welding starting point A and a welding end point B by observing an environment camera; and opening a welding path walking teaching function, firstly adjusting the machine head to be at the point A, taking the determined point as a welding starting point, then adjusting the transverse motor and the longitudinal motor on the three-axis moving platform to enable the machine head to reach the point B, and taking the determined point as a welding end point. And finally, adjusting a transverse motor and a longitudinal motor on the three-axis moving platform to reach a welding starting point A.
(4) And (3) welding implementation:
transferring welding process data through a remote welding handle; then checking the water path and the gas path; the weld is then initiated.
In the welding process, an electric arc is formed between the welding torch and the water wall, the welding wire is continuously fed into the molten pool, and the forming quality of the surfacing welding seam can be observed through the molten pool monitoring camera; according to the voltage data acquisition result, the arc height self-adaptive module continuously adjusts the distance between the machine head and the water-cooled wall, and the distance between the welding torch and the water-cooled wall is kept unchanged according to a numerical value specified by a welding process, so that the welding quality is ensured. According to the walking planning of the welding path, the position of the welding head is continuously adjusted by the transverse moving motor and the longitudinal moving motor on the three-axis moving platform, and the walking of the welding head is ensured to meet the actual welding requirement.
And (4) after the first surfacing welding seam is finished, continuously repeating the step (3), and then performing welding until the welding is finished.
(5) And (3) returning the wall climbing robot and the water wall on-site automatic surfacing device:
after surfacing is completed, the three-axis mobile platform is adjusted to the highest height so as to prevent collision between a welding torch and a water-cooled wall when the wall-climbing robot walks, the wall-climbing robot is controlled to return to the position near a manhole by an observation environment camera and an adjusting remote controller, a robot power supply and a control box power supply are turned off, a safety rope is removed, and finally, the wall-climbing robot and the on-site automatic surfacing device of the water-cooled wall are disassembled to be transported out of the manhole.
Claims (6)
1. The utility model provides a water-cooling wall on-spot automatic surfacing device based on self-adaptation principle which characterized in that: the welding device comprises a three-axis mobile platform (17), a welding torch (1), an environment camera (2), a molten pool monitoring camera (3), an electric arc height self-adaption module (4), an arc voltage acquisition module (5), a wire feeding system (6) and a welding wire position adjusting module (7).
2. The self-adaptive principle-based on-site automatic surfacing device for the water cooled wall according to claim 1, characterized in that: triaxial moving platform include support (8), transverse motor (9), transverse shifting beam (10), vertical motor (11), vertical shifting beam (12), upper and lower motor (13) and upper and lower shifting beam (14), install above triaxial moving platform (17) support (8), wholly fix on climbing wall robot (16) body through fixing bolt (15).
3. The self-adaptive principle-based on-site automatic surfacing device for the water cooled wall according to claim 1, characterized in that: the welding torch comprises an environment camera (2), a molten pool monitoring camera (3), a welding wire position adjusting module (7) and a welding torch (1), wherein the whole welding torch is fixed on the arc height self-adaptive module (4) through bolts.
4. The self-adaptive principle-based on-site automatic surfacing device for the water cooled wall according to claim 1, characterized in that: the arc height self-adaptive module (4) comprises an adjusting motor, a gear, a rack, an arc voltage acquisition module (18) and an arc height controller.
5. The self-adaptive principle-based on-site automatic surfacing device for the water cooled wall according to claim 1, characterized in that: the wire feeding system (6) comprises a wire reel (19), a wire feeding mechanism (20) and a welding wire correcting mechanism, and the whole body is fixed on the longitudinal moving beam (12) of the three-axis moving platform (17) through bolts.
6. The self-adaptive principle-based on-site automatic surfacing device for the water cooled wall according to claim 1, characterized in that: the arc voltage acquisition module (18) is arranged outside the welding torch (1).
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202011255828.3A CN112475538A (en) | 2020-11-11 | 2020-11-11 | Water-cooled wall on-site automatic surfacing device based on self-adaptive principle |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202011255828.3A CN112475538A (en) | 2020-11-11 | 2020-11-11 | Water-cooled wall on-site automatic surfacing device based on self-adaptive principle |
Publications (1)
Publication Number | Publication Date |
---|---|
CN112475538A true CN112475538A (en) | 2021-03-12 |
Family
ID=74929631
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CN202011255828.3A Pending CN112475538A (en) | 2020-11-11 | 2020-11-11 | Water-cooled wall on-site automatic surfacing device based on self-adaptive principle |
Country Status (1)
Country | Link |
---|---|
CN (1) | CN112475538A (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN117840595A (en) * | 2024-01-26 | 2024-04-09 | 唐山润兴机械有限公司 | Surfacing equipment for producing wear-resistant composite steel plate and welding method thereof |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2006089322A1 (en) * | 2005-02-25 | 2006-08-31 | Fronius International Gmbh | Method for controlling and/or regulating a welding device, and welding device |
CN102091878A (en) * | 2010-12-30 | 2011-06-15 | 黑龙江省电科能源工程技术有限公司 | Bead welding device and method for wear-resistant layer on water-cooled wall by using MIG (Metal-Inert Gas) and flux-cored wire |
US20140131333A1 (en) * | 2012-11-13 | 2014-05-15 | Adaptive Intelligent Systems Llc | Method to monitor and control weld penetration in gas tungsten welding and full-position pipe welding |
CN106925922A (en) * | 2017-03-24 | 2017-07-07 | 西北工业大学 | Self adaptation laser binocular seam tracking system |
CN109834373A (en) * | 2017-11-28 | 2019-06-04 | 史和生 | A kind of view-based access control model and the automation submerged arc soldering equipment of laser tracking |
CN210080984U (en) * | 2019-02-20 | 2020-02-18 | 广东省智能制造研究所 | Multifunctional wall climbing welding robot system |
CN111054999A (en) * | 2020-01-25 | 2020-04-24 | 济南金鲁鼎焊接技术有限公司 | Pipeline all-position automatic TIG welding machine and welding process thereof |
CN111531303A (en) * | 2020-06-16 | 2020-08-14 | 成都阿朗科技有限责任公司 | Automatic welding trolley, device and control method |
-
2020
- 2020-11-11 CN CN202011255828.3A patent/CN112475538A/en active Pending
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2006089322A1 (en) * | 2005-02-25 | 2006-08-31 | Fronius International Gmbh | Method for controlling and/or regulating a welding device, and welding device |
CN102091878A (en) * | 2010-12-30 | 2011-06-15 | 黑龙江省电科能源工程技术有限公司 | Bead welding device and method for wear-resistant layer on water-cooled wall by using MIG (Metal-Inert Gas) and flux-cored wire |
US20140131333A1 (en) * | 2012-11-13 | 2014-05-15 | Adaptive Intelligent Systems Llc | Method to monitor and control weld penetration in gas tungsten welding and full-position pipe welding |
CN106925922A (en) * | 2017-03-24 | 2017-07-07 | 西北工业大学 | Self adaptation laser binocular seam tracking system |
CN109834373A (en) * | 2017-11-28 | 2019-06-04 | 史和生 | A kind of view-based access control model and the automation submerged arc soldering equipment of laser tracking |
CN210080984U (en) * | 2019-02-20 | 2020-02-18 | 广东省智能制造研究所 | Multifunctional wall climbing welding robot system |
CN111054999A (en) * | 2020-01-25 | 2020-04-24 | 济南金鲁鼎焊接技术有限公司 | Pipeline all-position automatic TIG welding machine and welding process thereof |
CN111531303A (en) * | 2020-06-16 | 2020-08-14 | 成都阿朗科技有限责任公司 | Automatic welding trolley, device and control method |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN117840595A (en) * | 2024-01-26 | 2024-04-09 | 唐山润兴机械有限公司 | Surfacing equipment for producing wear-resistant composite steel plate and welding method thereof |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CN112475767A (en) | Water-cooled wall on-site repairing method based on automatic surfacing technology | |
WO2017079995A1 (en) | Robot-based welding system and method | |
CN102350567B (en) | TIG (Tungsten Inert Gas) automatic overlay-welding device for all circumferential positions on inner surface of 90-degree bent pipe and welding method thereof | |
CN103267281B (en) | Deposition robot and deposition method for water-cooled wall of fluidized bed boiler | |
CN102974913B (en) | Special longitudinal seam inside welding machine for stainless steel and composite steel welded pipes and use and using method of special longitudinal seam inside welding machine | |
CN106141375B (en) | A kind of operating method of large-scale supporting roller built-up welding work station | |
KR101678307B1 (en) | Welding method of automatic welding apparatus for pressure vessel and steel pipe | |
CN214189851U (en) | Water-cooled wall intelligent modular maintenance platform based on wall-climbing robot | |
CN212526613U (en) | Single-side welding and double-side forming welding robot | |
CN111408840A (en) | Device for assisting underwater laser deposition or material increase through induction heating and use method | |
CN111633364A (en) | Single-side welding and double-side forming welding robot | |
CN107824937B (en) | Automatic backing welding process method for narrow groove of thick-wall pipe and welding head | |
CN112475538A (en) | Water-cooled wall on-site automatic surfacing device based on self-adaptive principle | |
CN201070701Y (en) | Novel girth welding device | |
CN115026483B (en) | Boiler water wall pipe weld joint identification welding method | |
CN110576245A (en) | full-automatic argon arc welding method for circular weld of duplex stainless steel pipeline | |
CN1111108C (en) | Hidden arc build-up welding method for repairing internal surface of pipe-casting mould | |
CN107030446A (en) | The online repair system of high temperature and high pressure steam valve sealing face | |
CN111438449A (en) | 3D printing remanufacturing process and system for flange of nuclear power plant | |
CN106238993A (en) | One is applicable to penstock stiffening ring automatic welding system and welding method | |
CN210908432U (en) | Automatic brazing system of solar panel core frame | |
KR101240275B1 (en) | Auto-welding machine for repairing penetration nozzle in primary system of nuclear power plant | |
Makhlin et al. | Single-and multioperator systems for automatic welding of position butt joints of nuclear power plant piping | |
CN208362430U (en) | A kind of automatic ultrasonic impact elimination welding residual stress device | |
CN109514058B (en) | Water erosion prevention treatment method for last-stage blade of steam turbine |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PB01 | Publication | ||
PB01 | Publication | ||
SE01 | Entry into force of request for substantive examination | ||
SE01 | Entry into force of request for substantive examination | ||
RJ01 | Rejection of invention patent application after publication | ||
RJ01 | Rejection of invention patent application after publication |
Application publication date: 20210312 |