CN115628448A - Temperature control system and temperature control method for submerged arc welding workpiece - Google Patents
Temperature control system and temperature control method for submerged arc welding workpiece Download PDFInfo
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- CN115628448A CN115628448A CN202211260124.4A CN202211260124A CN115628448A CN 115628448 A CN115628448 A CN 115628448A CN 202211260124 A CN202211260124 A CN 202211260124A CN 115628448 A CN115628448 A CN 115628448A
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- 238000003466 welding Methods 0.000 title claims abstract description 146
- 238000000034 method Methods 0.000 title claims description 15
- 239000007789 gas Substances 0.000 claims abstract description 52
- 238000004891 communication Methods 0.000 claims abstract description 3
- 239000002737 fuel gas Substances 0.000 claims abstract description 3
- 238000010438 heat treatment Methods 0.000 claims description 11
- 238000002485 combustion reaction Methods 0.000 claims description 10
- 230000009471 action Effects 0.000 claims description 7
- 230000009699 differential effect Effects 0.000 claims description 5
- 230000010354 integration Effects 0.000 claims description 4
- 238000004364 calculation method Methods 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims description 3
- 238000010304 firing Methods 0.000 claims description 2
- 229910000831 Steel Inorganic materials 0.000 description 7
- 239000010959 steel Substances 0.000 description 7
- 230000008569 process Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000011217 control strategy Methods 0.000 description 1
- 230000004069 differentiation Effects 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/38—Torches, e.g. for brazing or heating
- F23D14/40—Torches, e.g. for brazing or heating for welding
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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
- B23K9/18—Submerged-arc 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
- B23K9/32—Accessories
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/46—Details, e.g. noise reduction means
- F23D14/60—Devices for simultaneous control of gas and combustion air
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- Combustion & Propulsion (AREA)
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Abstract
The invention discloses a temperature control system for a submerged arc welding workpiece, which comprises: a plurality of burners aligned to the back of the weld of the submerged arc welding workpiece at equal intervals along the direction of the weld; an ignition needle mounted on each of the burners to be ignited by a corresponding igniter; a check valve in communication with each of the burners via a conduit; the fuel gas proportional valve is communicated with each check valve through a pipeline; the gas meter is communicated with the plurality of gas proportional valves together and communicated with a gas pipeline; the temperature sensors are arranged on the front side of a welding seam of the submerged-arc welding workpiece and used for respectively measuring the temperature of the submerged-arc welding workpiece corresponding to each combustor; and the controller is electrically connected with each igniter, each gas proportional valve, each temperature sensor and the gas meter respectively. The temperature of the submerged-arc welding workpiece is accurately controlled, and the welding quality of the submerged-arc welding is improved.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a temperature control system and method for a submerged arc welding workpiece.
Background
The temperature has a great influence on the performance of steel, particularly on the mechanical properties of the steel at high temperature, such as the tensile strength, yield point, impact toughness, creep limit and holding limit of the steel are all reduced, and therefore, the welding temperature needs to be controlled in the welding process. The submerged arc welding is suitable for welding methods adopted in manufacturing of important steel structures such as pressure vessels, large pipe sections, box-type beam columns and the like, has the advantages of stable welding quality, high welding efficiency, no arc light, less smoke and the like, generally adopts gas to heat steel plates in the welding process, but is simple to control, mostly adopts a manual control mode, and cannot automatically adjust the gas flow, so that the heating temperature of the steel plates is not uniform in the heating process, the welding quality is influenced, and the gas use efficiency is low due to the adoption of the simple control mode, so that the energy conservation and emission reduction are not facilitated.
Disclosure of Invention
The invention aims to provide a temperature control system and a temperature control method for a submerged-arc welding workpiece, which can accurately control the temperature of the submerged-arc welding workpiece and improve the welding quality of the submerged-arc welding.
The technical scheme for realizing the purpose is as follows:
a submerged arc welding workpiece temperature control system comprising:
a plurality of burners aligned to the back of the weld of the submerged arc welding workpiece at equal intervals along the direction of the weld;
an ignition needle mounted on each burner and ignited by a corresponding igniter;
a check valve in communication with each of the burners via a conduit;
the fuel gas proportional valve is communicated with each check valve through a pipeline;
the gas meter is communicated with the plurality of gas proportional valves together and communicated with a gas pipeline;
the temperature sensors are arranged on the front side of a welding seam of the submerged-arc welding workpiece and used for respectively measuring the temperature of the submerged-arc welding workpiece corresponding to each combustor;
and the controller is electrically connected with each igniter, each gas proportional valve, each temperature sensor and the gas meter respectively.
Preferably, the submerged-arc welding gun is aligned to the front side of a welding seam of the submerged-arc welding workpiece, the submerged-arc welding gun is driven by the welding trolley, the welding trolley is provided with an encoder for calculating the walking distance of the welding trolley, and the encoder is electrically connected with the controller.
Preferably, each gas proportional valve is electrically connected with the controller through a corresponding AD module;
and each temperature sensor and each gas meter are respectively electrically connected with the controller through the corresponding Al module.
Preferably, the welding trolley drives the submerged arc welding gun to move along the direction of the welding seam;
the controller controls the plurality of burners to sequentially and sectionally heat according to the walking distance of the welding tractor calculated by the encoder,
wherein the controller controls the igniter and the gas proportional valve to make each burner based on a formula:
carrying out a combustion control in which, among others,
y: PID (proportion integration differentiation) algorithm output value used for controlling the voltage output by the AD (analog digital output) module and controlling the opening of the gas proportional valve through the voltage output by the AD module; k is a radical of formula p : proportional gain, b: proportional action weight, w: temperature set value, x: temperature course value, T I : integration time of action, a: differential delay coefficient, T D : differential action time, S1: a laplacian variant; c: the weight of the differential action.
Preferably, the temperature sensor is represented by the formula:
collecting temperature information;
wherein A is max : maximum value of AI (analog digital input) module input, A min : minimum value of AI Module input, B max : maximum value of measuring range of sensor, B min : sensor measurement range minimum, χ 1: AI module input value, γ: and outputting the actual measured value.
Preferably, the walking distance S of the welding carriage is calculated by the formula:
calculating to obtain;
wherein D is the diameter of the roller of the welding tractor; p is the number of pulses generated by one rotation of the encoder; and A is the number of pulses from the encoder obtained by the controller.
Preferably, the number of burners is 3, and the burners are a first burner, a second burner and a third burner.
The temperature control method of the submerged arc welding workpiece temperature control system comprises the following steps:
step S1, setting temperature curves of a first combustor, a second combustor and a third combustor, and controlling heating time T by temperature S Value assigned S da ＝S de -T S *v，S db ＝S df -T S *v，S dg (ii) a Wherein v is the welding speed of the submerged arc welding torch, S de A single burner length; s df Two burner lengths; s. the dg Three burner lengths;
the following steps are executed in parallel:
s2, collecting temperature information by the three temperature sensors through a formula II; the controller calculates according to a formula I and controls the opening of each gas proportional valve according to the calculation result;
s3, judging whether the temperature information acquired by the temperature sensor corresponding to the first combustor reaches a preset welding temperature T or not, and if so, calculating the walking distance S of the welding trolley through a formula III;
s4, starting, igniting a first combustor, heating the submerged-arc welding workpiece, enabling temperature information collected by a temperature sensor corresponding to the first combustor to reach a preset welding temperature, and moving a welding trolley;
when S-S da If the temperature is higher than 0, igniting the second combustor;
when S-S de If the temperature is higher than 0, stopping the fire of the first burner;
when S-S db If the temperature is more than 0, igniting the third combustor;
when S-S df If the temperature is more than 0, stopping the fire of the second burner;
when S-S dg And (5) stopping the fire of the third burner if the temperature is higher than 0 ℃.
The beneficial effects of the invention are: according to the invention, the burners are controlled to be sequentially heated in a segmented manner from the starting point of the welding line, different burners are accurately controlled to be ignited at different positions, the proportional valve is adjusted in real time, the use of gas is controlled to the maximum extent, and the use amount of the gas is effectively saved. Through a temperature control algorithm and an accurate control flow, the temperature of the submerged-arc welding workpiece is accurately controlled, the temperature control is prevented from being inaccurate, and therefore the welding quality of the submerged-arc welding is improved.
Drawings
FIG. 1 is a schematic structural diagram of a submerged arc welding workpiece temperature control system of the present invention;
FIG. 2 is a connection diagram of a controller according to the present invention;
FIG. 3 is a schematic view of the welding carriage of the present invention;
FIG. 4 is a schematic view of a temperature control strategy according to the present invention;
fig. 5 is a flow chart of a temperature control method of the present invention.
Detailed Description
The invention will be further explained with reference to the drawings.
Referring to fig. 1-4, the temperature control system for a submerged arc welding workpiece of the present invention comprises: an equal number of burners, ignition needles 2, igniters 3, check valves 4, temperature sensors 5, gas proportional valves 6, gas meters 7, and a controller 8. In the present embodiment, the number of burners is 3, and the burners are a first burner 119, a second burner 120, and a third burner 121.
The submerged arc welding process is used for welding steel plates, which are generally ultra-thick and ultra-wide, so that the submerged arc welding workpiece 13 is heated.
The burners are aligned at equal intervals in the direction of the weld to the back of the weld of the submerged arc welding workpiece 13. An ignition needle 2 is mounted on each burner to be ignited by a corresponding igniter 3. The check valve 4 communicates with each corresponding burner through a pipe. The gas proportional valve 6 is communicated with each corresponding check valve 4 through a pipeline. The gas meter 7 is communicated with a plurality of gas proportional valves 6 together and communicated with a gas pipeline 131. The gas pipeline 131 is connected with a plant gas outlet.
The temperature sensor 5 is arranged on the front surface of a welding seam of the submerged arc welding workpiece 13 and is used for measuring the temperature of the submerged arc welding workpiece corresponding to each combustor.
The controller 8 is electrically connected to each igniter 3, each gas proportional valve 6, each temperature sensor 5, and the gas meter 7, respectively, to control them. Specifically, each gas proportional valve 6 is electrically connected with the controller 8 through the corresponding AD module 9; the temperature sensors 5 and the gas meters 7 are electrically connected to the controller 8 through corresponding Al modules 10. The temperature sensors 5 correspond to the gas proportional valves 6 one by one.
The gas proportional valve 6 adjusts the opening of the valve based on the input voltage, adjusts the flow of the control gas, controls the flame size of the gas and meets the requirement of workpiece temperature control. The controller 8 can also be connected with an upper computer to improve the data processing capability.
The submerged arc welding gun 12 is aligned to the front face of the welding seam of the submerged arc welding workpiece 13, the submerged arc welding gun 12 is driven by the welding trolley 312, the welding trolley 312 is provided with an encoder 311 for calculating the walking distance of the welding trolley, and the encoder 311 is electrically connected with the controller 8. In this embodiment, the roller 313 drives the welding carriage 312 to move, and the encoder 311 is mounted on the roller 313. The welding carriage 312 drives the submerged arc welding gun 12 to move along the direction of the weld joint.
The controller 8 controls the plurality of burners to sequentially and sectionally heat according to the welding carriage walking distance S calculated by the encoder 311, generally, the first burner (the first burner 119) burns, when the working temperature starts to rise and reaches the preset welding temperature T, welding is started, the welding carriage 312 moves, and the encoder 311 starts to count. As shown in fig. 4, point D is a welding start point.
Wherein, the controller 8 makes each combustor based on the formula by controlling the corresponding igniter 3 and the corresponding gas proportional valve 6:
performing a combustion control in which, among others,
y: the PID algorithm output value is used for controlling the voltage output by the AD module, and the opening of the gas proportional valve is controlled through the voltage output by the AD module; k is a radical of p : proportional gain, b: proportional action weight, w: temperature setting value, x: and the temperature process value is obtained by a temperature sensor. T is I : integration time of action, a: differential delay coefficient, T D : differential action time, S1: a Laplace variate; c: the weight of the differential action.
When the welding tractor 312 reaches the point A, the second combustor 120 starts ignition combustion to heat the submerged-arc welding workpiece 13, and the temperature is changed according to the set curve of the second combustor 120 so as to preheat the submerged-arc welding workpiece 13 in advance; when the welding carriage 312 reaches the point E, the first burner 119 is extinguished and does not burn any more since the second burner 120 has started to operate and the temperature has reached the preset welding temperature T (120 ℃ in the present embodiment); the second combustor 120 also performs combustion control based on the formula one; continuing welding, when the welding trolley 312 reaches the point B, starting ignition combustion by the third combustor 121 to heat the submerged-arc welding workpiece 13, and changing the temperature according to the setting curve of the third combustor 121; when the welding tractor 312 reaches the point F, the third burner 121 starts to work, the temperature reaches the preset welding temperature T, and the second burner 120 is extinguished and does not burn any more; the third burner 121 also performs combustion control based on the formula one, and when the welding carriage 312 reaches the point G, the welding is finished and a next welding command is waited for.
The temperature sensor 5 is represented by the formula:
collecting temperature information; on the one hand, data feedback to the controller 8 is required, and on the other hand, applications such as display, storage and the like are required.
Wherein A is max : maximum value of AI Module input, A min : minimum value of AI Module input, B max : maximum value of measuring range of sensor, B min : minimum sensor measurement range, x1: AI module input value, γ: and outputting the actual measured value.
The walking distance S of the welding tractor is determined by a formula:
calculating to obtain;
wherein D is the diameter of the roller 313 of the welding carriage 312; p is the number of pulses generated by one rotation of the encoder 311; a is the number of pulses from the encoder 312 obtained by the controller 8.
In the embodiment, the combustor is a completely premixed combustor, the excess air is less (alpha = 1.05-1.10), the combustion is complete, the chemical incomplete combustion is less, the workpiece is not excessively oxidized, the combustion temperature is high, and the combustor is easy to fillThe requirement of high temperature process is satisfied, no air blast is needed, and electric energy and air blast equipment are saved. By adjusting k p : proportional gain, b: proportional action weight, a: the differential delay coefficient achieves accurate temperature control. Through to each combustor independent control, at the welded in-process, have a combustor to be in the stop condition, a combustor is in the state of heating, and a combustor goes out to be in the temperature and keeps the temperature control state, ignites in the position of difference through different combustors of accurate control, and the maximize control gas uses, effectively practices thrift the gas quantity.
Referring to fig. 4-5, the temperature control method based on the temperature control system for submerged arc welding workpieces of the present invention includes the following steps:
step S1, setting temperature curves of a first combustor 119, a second combustor 120 and a third combustor 121, and controlling the heating time T by temperature S Value assigned S da ＝S de -T S *v，S db ＝S df -T S *v，S dg (ii) a Wherein v is the welding speed of the submerged arc welding gun, S de A single burner length (in the present embodiment, a single burner length of 1000 mm); s df Two burner lengths; s dg Three burner lengths. Starting a control system n =1, executing the following steps, wherein the steps 2, 3 and 4 are parallel execution steps, the step 4 is a main control step, and the steps 2, 3 and 4 change the flow execution by exchanging data through variables;
s2, collecting temperature information by the three temperature sensors 5 through a formula II; the controller 8 calculates through a formula I, and controls the opening degree of each gas proportional valve 6 according to the calculation result. The temperature measuring range of the temperature sensor 5 is 0 ℃ to +500 ℃, and the value B is assigned min =0, value B max =500; the data acquisition module selects an SM1232 Al 4'13 bit full-scale range: 0 to 27648, value A max =27648, assign a min =0; and executing a second formula to calculate the real-time temperature. Judging whether n is equal to 0 (n =1 represents system start, n =0 represents system stop), and when n =0, circularly executing the step 2, calculating heating of the submerged arc welding workpiece 13 in real time, and controlling the gas proportional valve 6 in real timeThe opening degree is controlled accurately to control the temperature.
And S3, judging whether the temperature information acquired by the temperature sensor corresponding to the first combustor reaches a preset welding temperature T or not, and if so, calculating the walking distance S of the welding tractor through a formula III. It is possible to perform welding by judging whether j is 1 (1 represents that the temperature of the workpiece has reached the requirement of the temperature setting control, corresponding to point D of fig. 4; 0 represents that welding has not started). In this embodiment, D =50 (mm), C =1200 (ohm long 0mron encoder E6B2-CWZ5G-P-1200, 1200 pulses are generated by one rotation of the roller), and the cycle is executed. When j =0, the loop ends.
Step S4, when the starting program n =1, igniting the first combustor 119, heating the submerged arc welding workpiece 13, and moving the welding trolley 312 when the temperature information acquired by the temperature sensor corresponding to the first combustor reaches a preset welding temperature T (T1-T is more than 0); the value of j =1 can be assigned to the welding j (j is a welding machine operation flag, 1 is a welding machine operation, and 0 is a welding machine stop).
Program loop, judge S-S da If the judgment result is more than 0, the submerged arc welding gun 12 is judged to reach the point D, and the second combustor 120 can be ignited; program loop, judge S-S de If the temperature is more than 0, when the temperature is judged to be more than 0, the submerged arc welding gun 12 is indicated to leave the heating area of the first combustor 119, and the first combustor 119 can be stopped to heat; program loop when S-S db If > 0, the third burner 121 is ignited; judgment of S-S df If the temperature is more than 0, if yes, the second combustor 120 stops firing and stops burning; program loop, judge S-S dg And if the welding condition is more than 0, stopping the welding machine when the third burner 121 is judged to be in the established condition, indicating that the welding of the welding line is finished, and stopping the welding machine, wherein the values are n =0 and j =0, and the temperature control system finishes the work when the welding is finished.
The above embodiments are provided only for illustrating the present invention and not for limiting the present invention, and those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and therefore all equivalent technical solutions should also fall within the scope of the present invention, and should be defined by the claims.
Claims (8)
1. A submerged arc welding workpiece temperature control system, comprising:
a plurality of burners aligned with the back of the weld seam of the submerged arc welding workpiece at equal intervals along the direction of the weld seam;
an ignition needle mounted on each burner and ignited by a corresponding igniter;
a check valve in communication with each of the burners via a conduit;
the fuel gas proportional valve is communicated with each check valve through a pipeline;
the gas meter is communicated with the plurality of gas proportional valves together and communicated with a gas pipeline;
the temperature sensors are arranged on the front side of a welding seam of the submerged-arc welding workpiece and used for respectively measuring the temperature of the submerged-arc welding workpiece corresponding to each combustor;
and the controller is electrically connected with each igniter, each gas proportional valve, each temperature sensor and the gas meter respectively.
2. The submerged arc welding workpiece temperature control system of claim 1, characterized in that the submerged arc welding torch is aligned with the front side of the weld seam of the submerged arc welding workpiece and is driven by the welding trolley, the welding trolley is provided with an encoder for calculating the walking distance of the welding trolley, and the encoder is electrically connected with the controller.
3. The submerged arc welding workpiece temperature control system of claim 2, characterized in that each gas proportional valve is electrically connected to the controller through a respective AD module;
and each temperature sensor and each gas meter are respectively electrically connected with the controller through the corresponding AI module.
4. The submerged arc welding workpiece temperature control system of claim 3, wherein the welding carriage drives the submerged arc welding torch to move in the direction of the weld;
the controller controls the plurality of burners to sequentially and sectionally heat according to the walking distance of the welding tractor calculated by the encoder,
wherein the controller controls the igniter and the gas proportional valve to enable each burner to be based on a formula:
performing a combustion control in which, among others,
the PID algorithm output value is used for controlling the voltage output by the AD module, and the opening of the gas proportional valve is controlled by the voltage output by the AD module; k is a radical of p : proportional gain, b: proportional action weight, w: temperature set value, x: temperature course value, T I : integration time of action, a: differential delay coefficient, T D : differential action time, S1: a Laplace variate; c: the weight is differentiated.
5. A submerged arc welding workpiece temperature control system as claimed in claim 4, characterised in that the temperature sensor is determined by the formula:
collecting temperature information;
wherein A is max : maximum value of AI Module input, A min : minimum value of AI Module input, B max : maximum value of measuring range of sensor, B min : sensor measurement range minimum, χ 1, ai module input value, γ: and outputting the actual measured value.
6. A submerged arc welding workpiece temperature control system as claimed in claim 5, characterised in that the welding carriage travel distance S is determined by the formula:
calculating to obtain;
wherein D is the diameter of the roller of the welding trolley; p is the number of pulses generated by one rotation of the encoder; and A is the number of pulses from the encoder obtained by the controller.
7. A submerged arc welding workpiece temperature control system as claimed in claim 6, characterised in that the number of burners is 3, being the first burner, the second burner and the third burner respectively.
8. A temperature control method based on the submerged arc welding workpiece temperature control system of claim 7, characterized by comprising:
step S1, setting temperature curves of a first combustor, a second combustor and a third combustor, and controlling heating time T by temperature S Value assigned S da ＝S de -T S *v，S db ＝S df -T S *v，S dg (ii) a Wherein v is the welding speed of the submerged arc welding torch, S de A single burner length; s df Two burner lengths; s. the dg Three burner lengths;
the following steps are executed in parallel:
s2, collecting temperature information by the three temperature sensors through a formula II; the controller calculates according to a formula I and controls the opening of each gas proportional valve according to the calculation result;
s3, judging whether the temperature information acquired by the temperature sensor corresponding to the first combustor reaches a preset welding temperature T or not, and if so, calculating the walking distance S of the welding trolley through a formula III;
s4, starting, igniting a first combustor, heating the submerged-arc welding workpiece, enabling temperature information collected by a temperature sensor corresponding to the first combustor to reach a preset welding temperature, and moving a welding trolley;
when S-S da >0, igniting the second combustor;
when S-S de >0, stopping firing the first burner;
when S-S db >0, igniting the third combustor;
when S-S df >0, stopping the fire of the second burner;
when S-S dg >And 0, stopping the fire of the third burner.
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