CN101745724B - Electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device and method thereof - Google Patents

Abstract

The invention discloses an electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device and a method thereof. The device comprises a wire feed system, a welding power source, a magnetic field power source, a copper gasket system, a torch system, an electromagnetic compound system and a numerical control system, wherein the wire feed system is formed by integrating the rotor of the electromagnetic direct-drive rotating servomotor and the main wire feed rolls into an integral body; the torch system comprises an eccentric current contact nozzle which is divided into an upper part and a lower part; the electromagnetic compound system is integrated with the nozzle of the torch system and a water cooling system into an integral body; and the copper gasket system is an air-pressure copper-gasket one-side-welding double-side one-step molding system, and the back side uses flux. The invention can cancel the mechanical transmission link between the traditional motor and the wire feed rolls, greatly enhances the wire feed stability and the control response precision, and eliminates the noise, oil sludge and vibration, thereby realizing the double-wire high-speed electromagnetic compound submerged arc welding one-side-welding double-side molding high-efficiency welding method. The method has the advantages of simple structure, small size, high stability and reliability, and precise numerical control, and can be used for welding huge and thick plates.

Description

Electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device and method thereof

Technical field

The present invention relates to welding field, particularly a kind of electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper lining submerged arc welding novel device and welding method thereof.

Background technology

Along with China's rapid development of economy; The needs that need develop at a high speed at many industrial circles, efficient and high-quality solder technology satisfy nation-building, the progress of related discipline science and technology has impelled modern welding new method constantly to occur simultaneously; Speed of welding improves constantly; Welding quality requires also to improve thereupon, and in addition, sustainable development, environmental protection also progressively improve the requirement of solder technology.

The submerged arc welding technology is that present China is applied to low-alloy high-strength steel, slab, long slab and welds one of most important solder technology, uses very extensively in fields such as building, boats and ships, pressure vessel, electric power, chemical industry, heavy-duty machineries.In recent years, mariages or the application of multiplewire submerged arc welding technology in above-mentioned field make its welding quality and welding efficiency be greatly improved, and have opened up a new welding technology field.But at present, still there are many shortcomings in traditional monofilament, mariages or multiplewire submerged arc welding connection technology:

1) welding joint mechanical property, particularly impact flexibility has much room for improvement;

2) the weld heat input restriction is strict, has limited the advantage of multiplewire submerged arc welding connection technology;

3) weld procedure specification is narrower;

4) weldering of mariages or multifibres causes weld metal crystal grain thick easily, pore, segregation, be mingled with, defective such as undercut is more;

5) speed of welding and welding efficiency also have much room for improvement;

6) welding material, outstanding like the environmental issue of solder flux, welding slag;

7) owing to adopt mechanisms such as turbine and worm transmission, gear reduction, make welding gun and welding equipment heavy, bulky, multifibres welding equipment complex structure has influenced arranging of many welding wires, is unfavorable for using operating difficulties.

Therefore, need further improve and development submerged arc welding device and technology, particularly double wire hidden arc welding connect equipment and welding method,, high-quality efficient to realize, novel multiplewire submerged arc welding connects equipment and development of technology cheaply.

Summary of the invention

The objective of the invention is to provide that a kind of slab is efficient to the deficiency of prior art, high-quality, low-cost mariages at a high speed, efficient submerged arc welding device and method; So that break through the limitation of traditional submerged arc welding device and method; And to the harsh requirement of welding condition; The realization impact property is good, and the multiplewire submerged arc welding of big electric current, high-speed, high efficiency, high-quality welded joint connects.

In view of this, the present invention adopts the electromagnetic direct-drive servomotor, through mechanical transmission mechanisms such as the turbine and worm between cancellation wire feed drive motors and the wire feed system, gear reductions, realizes the zero transmission between motor and the wire feed rolls, can accomplish high speed wire feed task; Effect at electromagnetic complex field realizes Electromagnetic Control submerged arc welding process, has obtained the distinct advantages of electromagnetic action submerged arc welding under the big welding current service condition; Simultaneously; Organically combine with flux copper-gasket single face welding and double face shaping welded and high efficient technology; Realize the high-quality moulding of weld seam positive and negative, under the support of digital power and Numeric Control Technology, realized efficiently, high-quality, at a high speed, double wire hidden arc welding connects equipment and new method thereof cheaply.

It is following that the present invention solves the concrete scheme that its technical problem adopts:

The electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device comprises wire feed system, the source of welding current, magnetic field power supply, flux copper-gasket system, torch system, electromagnetism hybrid system, digital control system.

Further; Said wire feed system is that rotating shaft and the main wire feed rolls I of the electromagnetic direct-drive rotating servo motor I of welding wire I becomes one; The two-pack that is made up of directive wheel I that is arranged in the bottom and main wire feed rolls I is to accomplishing wire feed; Rotating shaft and the main wire feed rolls II of the electromagnetic direct-drive rotating servo motor II of welding wire II become one, and the two-pack that is made up of directive wheel II that is arranged in top and main wire feed rolls II is to accomplishing wire feed;

Said torch system comprises eccentric ignition tip I and eccentric ignition tip II, and eccentric ignition tip I is made up of the first half and the latter half, and eccentric ignition tip II is made up of the first half and the latter half;

Said electromagnetism hybrid system comprises taper magnet exciting coil, side plate, cover plate, following water inlet, upper water-out mouth, winding wire mouth; Nozzle, the water-cooling system of electromagnetism hybrid system and torch system become one; Add the electromagnetic field effect welding region through the field power supply generation; The electromagnetism blow in the welding process is eliminated in control welding arc and molten bath, improves the joint total quality of welding;

Said flux copper-gasket system comprises inflated hose, copper lining, liner solder flux; For being positioned over the vapour-pressure type flux copper-gasket system of back of weld; It is the uniform liner solder flux of spreading thickness on copper pad; And feed tracheae with compressed air, be attached to the copper pad that applies good solder flux with certain pressure the back side of weld seam;

Further, the directive wheel II of said wire feed system is arranged in main wire feed rolls I, same main shaft; Directive wheel I is connected through bearing with main shaft; Main wire feed rolls II is arranged in directive wheel I, same main shaft, and directive wheel I is connected through bearing with main shaft; Servomotor I and servomotor II are arranged above and below compact conformation;

Said welding wire I and welding wire II accomplish the function that welding process is filled weld metal jointly;

The gathering sill surface of said directive wheel I and directive wheel II is smooth, and the gathering sill surface of main wire feed rolls I and main wire feed rolls II is coarse decorative pattern lines, helps increasing wire feed frictional force, improves feeding stability;

Said wire feed system comprises clamp mechanism and preceding thread plate; It is right that wire feed rolls and corresponding with it pinch wheels constitute the wire feed wheel set; Pinch wheels makes welding wire closely contact with wire feed rolls, guarantees that welding wire can send to smoothly, and preceding thread plate stretches out the guiding welding wire and penetrates the welding wire guide hole very easily.

Further, the first half of said eccentric ignition tip I is connected by internal and external threads with the latter half, is convenient to dismounting and replacing; The first half has off-centre to a certain degree when being connected with the latter half, formed eccentric ignition tip, has guaranteed that welding wire I contacts with the good of ignition tip I; And the first half is longer, adopts more cheap Cu alloy material, has so just saved the chromium zirconium copper material of the costliness of half approximately; The latter half is shorter, adopts electric conductivity and the good chromium zirconium copper material of wearability, is convenient to endoporus fine finishining; Reach best conductive effect, conductive clip I links to each other with eccentric ignition tip I, independently for welding wire I welding current is provided;

The first half of said eccentric ignition tip II is connected through internal and external threads with the latter half, is convenient to dismounting and replacing, and the first half has off-centre to a certain degree when being connected with the latter half; Formed eccentric ignition tip, guaranteed that welding wire II contacts with the good of ignition tip II, and the first half has been longer; Adopt more cheap Cu alloy material, so just saved the chromium zirconium copper material of half the costliness approximately, the latter half is shorter; Adopt electric conductivity and the good chromium zirconium copper material of wearability, be convenient to endoporus fine finishining, reach best conductive effect; Conductive clip II links to each other with eccentric ignition tip II, independently for welding wire II welding current is provided;

Eccentric ignition tip I links to each other with torch body through insulation locating support I; Eccentric ignition tip II links to each other with torch body through insulation locating support II; Insulation locating support I and insulation locating support II are arranged in together, mutual insulating, also mutually insulated between eccentric ignition tip I and the eccentric ignition tip II; Guaranteed that the welding current between welding wire I and the welding wire II is separate, do not disturbed mutually;

Conductive clip I and conductive clip II select for use brass to do material, and the heat that has a resistance during welding is less, and the brass conductive folder is convenient to processing and better economy;

Ignition tip I and ignition tip II have the transition taper hole, make intermediate location level and smooth, and the dead turning of no transition can once mounting be accomplished welding wire, and work efficiency is high;

The length of conduction aperture is longer than general conductive hole length among ignition tip I and the ignition tip II; Guaranteed the contact distance of welding wire with ignition tip; Improve electric conductivity, prevented outage, electric arc shakiness and haircuts phenomenon effectively, improved the abrasion resistance of ignition tip simultaneously; Welding wire can carry out electric preheating in advance, helps welding.

Further; The magnet exciting coil of said electromagnetism hybrid system is the taper magnet exciting coil of up big and down small structure; Big magnetic field, little periphery, generation center, peripheral little distribution adapts with the welding current center is big, forms rational electromagnetic force at welding region; Control welding arc, welding pool, Welding Metallurgy overall process form quality weld;

Said electromagnetism hybrid system provides exciting current by magnetic field power supply, and generation both forward and reverse directions alternate, positive back pulse do not wait amplitude, the weak vertical rotating excitation field of pulse of strong gap alternating polarity all around in center;

The magnet exciting coil of said electromagnetism hybrid system is immersed in the cooling medium; And insulate with cooling medium; Cooling medium gets into from the following water inlet that is positioned at nozzle, flows out from the upper water-out mouth of the cover plate that is positioned at the nozzle top, guarantees that like this nozzle, magnet exciting coil have good cooling effect; Be applicable to the big electric current welding of submerged arc, simultaneously compact conformation, simple effective, reliable operation.

Further, said copper lining system is the welding system of flux copper-gasket single face welding and double face shaping, and the liner solder flux directly contacts with back of work; Under the liner solder flux copper lining is arranged, under the jacking supporting role of inflated hose, the solder flux liner is close to back of work; The size, particularly reinforcement of control back bead are used big welding current; Can form back bead, and also tolerant for its allowed band of variation of groove precision and welding condition, reliable welding quality.

A kind of electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper lining buried arc welding method; The high-efficiency high-quality buried arc welding method of digital control type mariages high speed electromagnetic compound flux copper-gasket single face welding and double face shaping comprises the function and the effect of mariages welded and high efficient, high-speed welding, electromagnetism composite welding, flux copper-gasket single face welding and double face shaping welded and high efficient, advanced digital control welding;

Further, said digital control type mariages welded and high efficient mode is under the support of electromagnetic direct-drive rotating servo motor, the machine driving link between having cancelled from the motor to the wire feed system; Carry out zero transmission mode; All under the digital control pattern of electrical quantity, realize the wire feed of quick and stable, and respond fast and feedback regulation wire feed state according to the actual welding situation, independent mutually between the mariages; Establish one's own system, can carry out the coordinated movement of various economic factors and adjusting according to the welding needs again simultaneously; Welding wire I is preceding; Welding wire II after front and back pattern of rows and columns, when welding wire I bears the function of bottoming before the weldering, the preheating of weld seam initial stage and postwelding capping, the direct current welding current is provided by source of welding current I; Welding wire II provides welding current by source of welding current II; The common function of filling weld seam of accomplishing realizes bottoming, preheating, capping, the one step completed welded and high efficient of joint filling, can high efficiency accomplish thick plates; Perhaps, be arranged side by side the common function of filling weld seam of accomplishing, the welded and high efficient of realization bottoming, preheating, capping, joint filling at welding wire I and welding wire II;

Further, said high-speed welding mode is under the support of mariages, big electric current, high speed wire feed, to realize high-speed welding, and mariages is not only independent but also cooperate; Can set wire feed rate respectively; Realize the combined type wire feeding mode, and carry out the adjusting of single welding wire feeding speed, realize the high-speed double-wire welding process according to welding sequence; The wire feed rate of welding wire I and welding wire II cooperatively interacts and welds; High-speed welding speed is 0.6m/min-5m/min, and welding current is 400-1200A, and gage of wire is 1.2mm-6.4mm;

Further, said electromagnetism composite welding mode is under the support of taper magnet exciting coil, field power supply, forms to dredge in close outward, the both forward and reverse directions Variable Polarity, do not wait vertical rotating excitation field of amplitude; Can eliminate arc blow or attraction under welding wire I direct current+welding wire II direct current combination condition, enlarge the electric arc area simultaneously, the rotation of control welding arc; Need not to swing the not fusion that just can eliminate groove or weld edge, and control welding pool and the metallurgical process of setting of weld seam, welding pool fully stirred; The crystalline condition of control weld metal impels the weld grain refinement, reduces chemical inhomogeneities; Reduce the sensitiveness of pore, reduce pore, slag inclusion, undercut defective, improve the toughness plasticity and the erosion-resisting ability of weld seam; Form quality weld, electromagnetism composite welding exciting current 10-50A, Variable Polarity excitation frequency 1-25Hz; Dutycycle 30%-70%, luffing are than 10%-50%, and interior external diameter magnetic field intensity is than being 20%-60%;

Further, the advantage that said flux copper-gasket single face welding and double face shaping welded and high efficient mode has fully utilized welding flux backing and copper lining forms, and the liner solder flux is powdery before solidifying; Be close to back of work, make back of weld force to be shaped after heat fused is solidified, solder flux is the solder flux of the ultralow hydrogen environmental protection of high tenacity of nanometer coating; Carry out submerged arc welding in the workpiece front, obtain the weld seam of one side welding with back formation, welded and high efficient slab or long slab; Can eliminate defectives such as back side motlten metal outflow, seaming; The size, particularly reinforcement of control back bead can be used big electric current; Excursion requirement for groove precision and welding condition is less, thereby realizes the high-quality and efficient welding of high tenacity;

Further; The digital control welding manner of said advanced person is all to adopt digital power at source of welding current I, source of welding current II and field power supply; Wire feed system adopts under the condition of electromagnetic direct-drive servomotor zero transmission; Whole welding system and welding procedure control all are advanced digital control models; Have remote monitoring, remote control and data transmission capabilities, realize that the close-loop control mode of response fast, even running, timely adjustment carries out omnibearing automatic control to each link of whole welding process, guarantee to obtain high-quality welded joint.

Beneficial effect of the present invention is mainly reflected in following aspect:

1) electromagnetic direct-drive rotating servo motor zero drive mechanism form: increased substantially feeding stability and control response precision, eliminated noise, greasy dirt and vibration, realized simple in structure, volume is little, reliable and stable, high speed wire feed that precision is controlled; Also make simultaneously the double-wire welding gun design become very simple; Compact conformation, the welding wire spread pattern is abundant, and spatial distribution is enough multiple; Can either establish one's own system between each welding wire, can coordinate each other again.

2) electromagnetic complex field: the vertical rotating excitation field control of pulse welding arc, welding pool and the weld seam process of setting of strong gap alternating polarity around not waiting a little less than amplitude, the center through both forward and reverse directions alternate, positive back pulse; The welding pool melt is fully stirred; Improve the crystalline condition of welding pool metal, change the distribution in welding process of setting and temperature field, cause the change of microstructure, phase structure; Impel the weld grain refinement; Reduce chemical inhomogeneities, reduce the sensitiveness of pore, make weld seam and heat affected area intensity thereof approach the intensity of mother metal; Eliminate the electromagnetism blow in the welding process, enlarge the electric arc area simultaneously, the rotation of control welding arc need not to swing the not fusion that just can eliminate groove or weld edge.

3) flux copper-gasket single face welding and double face shaping welded and high efficient: the advantage that has fully utilized welding flux backing and copper lining; The liner solder flux is close to back of work; Make back of weld force to be shaped; Solder flux is the solder flux of the ultralow hydrogen environmental protection of high tenacity of nanometer coating, carries out submerged arc welding in the workpiece front, obtains the weld seam of one side welding with back formation; At welded and high efficient slab or long slab, can eliminate defectives such as back side motlten metal outflow, seaming, the size of control back bead; Reinforcement particularly; Can use big electric current, less for the excursion requirement of groove precision and welding condition, thus realize the high-quality and efficient welding of high tenacity.

4) mariages arrangement mode: mariages mode arranged in a straight line, welding wire I is preceding, welding wire II after, the common function of filling weld seam of accomplishing, welding wire I also accomplishes bottoming, preheating, capping, the one step completed welding sequence of joint filling, can high efficiency accomplish thick plates; Perhaps welding wire I and welding wire II arrange side by side, the common welding all functions of accomplishing.

5) eccentric ignition tip and two halves structure up and down: ignition tip the first half is connected through internal and external threads with the latter half, is convenient to dismounting and changes, and the first half has off-centre to a certain degree when being connected with the latter half; Guaranteed that welding wire contacts with the good of ignition tip, the first half is longer, adopts more cheap Cu alloy material; So just saved the chromium zirconium copper material of half the costliness approximately, the latter half is shorter, adopts electric conductivity and the good chromium zirconium copper material of wearability; Be convenient to endoporus fine finishining; Reach best conductive effect, conductive clip links to each other with eccentric ignition tip, independently for welding wire welding current is provided; Mariages can use dissimilar welding currents, forms interchange, the multiple combination of direct current.

6) the wire feed wheel set is right: the two-pack that welding wire I and welding wire II are made up of directive wheel that is arranged in the bottom and main wire feed rolls can be realized the stable feeding of thick welding wire to accomplishing wire feed, improves joint filling efficient and deposition efficiency; Mariages can use different diameters.

7) advanced person's digital control welding manner: the source of welding current and field power supply all adopt digital power; Wire feed system adopts under the condition of electromagnetic direct-drive servomotor zero transmission; Whole welding system and welding procedure control all are advanced digital control models; Have remote monitoring, remote control and data transmission capabilities, realize that the close-loop control mode of response fast, even running, timely adjustment carries out omnibearing automatic control to each link of whole welding process, guarantee to obtain high-quality welded joint.

8) integrated water-cooling system: the magnet exciting coil of electromagnetism hybrid system is immersed in the cooling medium; And insulate with cooling medium; Cooling medium gets into from the following water inlet that is positioned at nozzle, flows out from the upper water-out mouth of the cover plate that is positioned at the nozzle top, guarantees that like this nozzle, magnet exciting coil have good cooling effect; Be applicable to the big electric current welding of submerged arc, simultaneously compact conformation, simple effective, reliable operation.

9) of many uses: as to be used for the welding of slab, super large slab, overlength plate; Be used for the welding of low-alloy high-strength steel, heat resisting steel, ultrafort steel, common stainless steel, two phase stainless steel; The welding of bevel and square groove; Narrow gap welding connects etc.; Speed of welding is fast; Welding efficiency is high, has efficient, low cost, high-quality, high stability, many applicabilities, multimode, the comprehensive characteristics that are prone to the advanced slab submerged-arc welding of control, has realized effective coordination and unification rationally efficient, high-quality; Reduce production cost, improved competitiveness of product; Solved the contradiction restriction between welding efficiency and the welding thickness of slab, two-sided welding one-shot forming, device structure is simple, cost is lower, and control is reliable, good stability, and weldquality is high, is easy to promote the use of.

The present invention is in shipbuilding, and the manufacturing and the equipment field of industry critical components such as boiler, oil, smelting and heavy-duty machinery have wide application value and development prospect, have realized the innovation of slab multiplewire submerged arc welding connection technology.

Description of drawings

Fig. 1 is a welding equipment sketch map of the present invention;

Fig. 2 is a mariages position view of the present invention;

Among the figure, 1. servomotor I; 2. servomotor II; 3. welding wire I guide hole; 4. welding wire II guide hole; 5. main wire feed rolls I; 6. directive wheel II; 7. directive wheel I; 8. gathering sill; 9. annular knurl groove; 10. main wire feed rolls II; 11. bearing; 12. preceding thread plate; 13. casing; 14. gripper shoe; 15. box side; 16. insulation locating support I; 17. insulation locating support II; 18. torch body; 19. ignition tip I the first half; 20. ignition tip I the latter half; 21. ignition tip II the first half; 22. ignition tip II the latter half; 23. conductive clip I; 24. conductive clip II; 25. cover plate; 26. delivery port; 27. side plate; 28. coil; 29. winding wire mouth; 30. cooling water; 31. nozzle; 32. water inlet; 33. welding wire I; 34. welding wire II; 35. nozzle inner walls; 36. workpiece; 37. groove; 38. copper lining; 39. liner solder flux; 40. inflated hose.

The specific embodiment

Below in conjunction with accompanying drawing and embodiment the present invention is further specified.

One. the electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device

A kind of electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device, concrete structure is following:

Referring to Fig. 1, Fig. 2, the electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device comprises wire feed system, the source of welding current, magnetic field power supply, flux copper-gasket system, torch system, electromagnetism hybrid system, digital control system;

Said wire feed system is that rotating shaft and the main wire feed rolls I5 of the electromagnetic direct-drive rotating servo motor I1 of welding wire I 33 becomes one; The two-pack that is made up of directive wheel I7 that is arranged in the bottom and main wire feed rolls I5 is to accomplishing wire feed; Rotating shaft and the main wire feed rolls II10 of the electromagnetic direct-drive rotating servo motor II2 of welding wire II34 become one, and the two-pack that is made up of directive wheel II6 that is arranged in top and main wire feed rolls II10 is to accomplishing wire feed;

Said torch system comprises eccentric ignition tip I and eccentric ignition tip II, and eccentric ignition tip I is made up of the first half 19 and the latter half 20, and eccentric ignition tip II is made up of the first half 21 and the latter half 22;

Said electromagnetism hybrid system comprises taper magnet exciting coil 28, side plate 27, cover plate 25, following water inlet 32, upper water-out mouth 26, winding wire mouth 29; The nozzle 31 of electromagnetism hybrid system and torch system, water-cooling system become one; Add the electromagnetic field effect welding region through the field power supply generation; The electromagnetism blow in the welding process is eliminated in control welding arc and molten bath, improves the joint total quality of welding;

Said flux copper-gasket system comprises inflated hose 40, copper lining 38, liner solder flux 39; For being positioned over the vapour-pressure type flux copper-gasket system of back of weld; It is the uniform liner solder flux of spreading thickness on copper pad; And feed tracheae with compressed air, be attached to the copper pad that applies good solder flux with certain pressure the back side of weld seam;

The directive wheel II6 of said wire feed system is arranged in main wire feed rolls I5; Same main shaft, directive wheel I7 is connected through bearing with main shaft, and main wire feed rolls II10 is arranged in directive wheel I7; Same main shaft; Directive wheel I7 is connected through bearing with main shaft, and servomotor I1 and servomotor II2 are arranged above and below compact conformation;

Said welding wire I33 and welding wire II34 accomplish the function that welding process is filled weld metal jointly; Welding wire I33 also accomplishes bottoming, preheating, capping, the one step completed welding sequence of joint filling;

The gathering sill surface of said directive wheel I7 and directive wheel II6 is smooth, and the gathering sill surface of main wire feed rolls I5 and main wire feed rolls II10 is coarse decorative pattern lines, helps increasing wire feed frictional force, improves feeding stability;

Said wire feed system comprises clamp mechanism and preceding thread plate 12; It is right that wire feed rolls and corresponding with it pinch wheels constitute the wire feed wheel set; Pinch wheels makes welding wire closely contact with wire feed rolls, guarantees that welding wire can send to smoothly, and preceding thread plate 12 stretches out the guiding welding wire and penetrates the welding wire guide hole very easily.

The first half 19 of said eccentric ignition tip I and the latter half 20 are connected through internal and external threads, are convenient to dismounting and change, and the first half 19 has off-centre to a certain degree when being connected with the latter half 20; Formed eccentric ignition tip, guaranteed that welding wire I33 contacts with the good of ignition tip I, and the first half 19 has been longer; Adopt more cheap Cu alloy material, so just saved the chromium zirconium copper material of half the costliness approximately, the latter half 20 is shorter; Adopt electric conductivity and the good chromium zirconium copper material of wearability, be convenient to endoporus fine finishining, reach best conductive effect; Conductive clip I23 links to each other with eccentric ignition tip I, independently for welding wire I33 welding current is provided;

The first half 21 of said eccentric ignition tip II and the latter half 22 are connected through internal and external threads, are convenient to dismounting and change, and the first half 21 has off-centre to a certain degree when being connected with the latter half 22; Formed eccentric ignition tip, guaranteed that welding wire II34 contacts with the good of ignition tip II, and the first half 21 has been longer; Adopt more cheap Cu alloy material, so just saved the chromium zirconium copper material of half the costliness approximately, the latter half 22 is shorter; Adopt electric conductivity and the good chromium zirconium copper material of wearability, be convenient to endoporus fine finishining, reach best conductive effect; Conductive clip II24 links to each other with eccentric ignition tip II, independently for welding wire II34 welding current is provided;

Eccentric ignition tip I links to each other with torch body 18 through insulation locating support I16; Eccentric ignition tip II links to each other with torch body 18 through insulation locating support II17; Insulation locating support I16 and insulation locating support II17 are arranged in together, mutual insulating, also mutually insulated between eccentric ignition tip I and the eccentric ignition tip II; Guaranteed that the welding current between welding wire I33 and the welding wire II34 is separate, do not disturbed mutually;

Conductive clip I and conductive clip II select for use brass to do material, and the heat that has a resistance during welding is less, and the brass conductive folder is convenient to processing and better economy;

Ignition tip I and ignition tip II have the transition taper hole, make intermediate location level and smooth, and the dead turning of no transition can once mounting be accomplished welding wire, and work efficiency is high;

The length of conduction aperture is longer than general conductive hole length among ignition tip I and the ignition tip II; Guaranteed the contact distance of welding wire with ignition tip; Improve electric conductivity, prevented outage, electric arc shakiness and haircuts phenomenon effectively, improved the abrasion resistance of ignition tip simultaneously; Welding wire can carry out electric preheating in advance, helps welding.

The magnet exciting coil 28 of said electromagnetism hybrid system is the taper magnet exciting coil of up big and down small structure; Big magnetic field, little periphery, generation center; Peripheral little distribution adapts with the welding current center is big; Form rational electromagnetic force at welding region, control welding arc, welding pool, Welding Metallurgy overall process form quality weld;

Said electromagnetism hybrid system provides exciting current by magnetic field power supply, and generation both forward and reverse directions alternate, positive back pulse do not wait amplitude, the weak vertical rotating excitation field of pulse of strong gap alternating polarity all around in center;

The magnet exciting coil of said electromagnetism hybrid system is immersed in the cooling medium; And insulate with cooling medium; Cooling medium gets into from the following water inlet that is positioned at nozzle 31 belows 32, flows out from the upper water-out mouth 26 of the cover plate 25 that is positioned at nozzle 31 tops, guarantees that like this nozzle 31, magnet exciting coil 28 have good cooling effect; Be applicable to the big electric current welding of submerged arc, simultaneously compact conformation, simple effective, reliable operation.

Said copper lining system is the welding system of flux copper-gasket single face welding and double face shaping, and liner solder flux 39 directly contacts with workpiece 36 back sides, and the liner solder flux has copper lining 38 39 times; Under the jacking supporting role of inflated hose 40, the solder flux liner is close to workpiece 36 back sides, the size of control back bead; Particularly reinforcement uses big welding current, can form back bead; And also tolerant for its allowed band of variation of groove precision and welding condition, reliable welding quality.

Two. electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper lining buried arc welding method

The high-efficiency high-quality buried arc welding method of digital control type mariages high speed electromagnetic compound flux copper-gasket single face welding and double face shaping comprises the function and the effect of mariages welded and high efficient, high-speed welding, electromagnetism composite welding, flux copper-gasket single face welding and double face shaping welded and high efficient, advanced digital control welding;

Said digital control type mariages welded and high efficient mode is under the support of electromagnetic direct-drive rotating servo motor; Machine driving link between having cancelled from the motor to the wire feed system is carried out zero transmission mode, all under the digital control pattern of electrical quantity, realizes the wire feed of quick and stable; And respond fast and feedback regulation wire feed state based on the actual welding situation; Independent mutually between the mariages, establish one's own system, can need carry out the coordinated movement of various economic factors and adjusting based on welding again simultaneously;

Welding wire I33 is preceding; Welding wire II34 after front and back pattern of rows and columns, when welding wire I33 bears the function of bottoming before the weldering, the preheating of weld seam initial stage and postwelding capping, the direct current welding current is provided by source of welding current I; Welding wire II34 provides welding current by source of welding current II; The common function of filling weld seam of accomplishing realizes bottoming, preheating, capping, the one step completed welded and high efficient of joint filling, can high efficiency accomplish thick plates;

Perhaps, be arranged side by side the common function of filling weld seam of accomplishing, the welded and high efficient of realization bottoming, preheating, capping, joint filling at welding wire I33 and welding wire II34;

Said high-speed welding mode is under the support of mariages, big electric current, high speed wire feed, to realize high-speed welding, and mariages is not only independent but also cooperate, and can set wire feed rate respectively; Realize the combined type wire feeding mode, and carry out the adjusting of single welding wire feeding speed, realize the high-speed double-wire welding process based on welding sequence; The wire feed rate of welding wire I and welding wire II cooperatively interacts and welds; High-speed welding speed is 0.6m/min-5m/min, and welding current is 400-1200A, and gage of wire is 1.2mm-6.4mm;

Said electromagnetism composite welding mode is under the support of taper magnet exciting coil 28, field power supply, forms to dredge in close outward, the both forward and reverse directions Variable Polarity, do not wait vertical rotating excitation field of amplitude, can eliminate arc blow or attraction under welding wire I direct current+welding wire II direct current combination condition; Enlarge the electric arc area simultaneously, the rotation of control welding arc need not to swing the not fusion that just can eliminate groove or weld edge; And the metallurgical process of setting of control welding pool and weld seam fully stirs welding pool, the crystalline condition of control weld metal; Impel the weld grain refinement, reduce chemical inhomogeneities, reduce the sensitiveness of pore; Reduce pore, slag inclusion, undercut defective, improve the toughness plasticity and the erosion-resisting ability of weld seam, form quality weld; Electromagnetism composite welding exciting current 10-50A, Variable Polarity excitation frequency 1-25Hz, dutycycle 30%-70%; Luffing is than 10%-50%, and interior external diameter magnetic field intensity is than being 20%-60%;

The advantage that said flux copper-gasket single face welding and double face shaping welded and high efficient mode has fully utilized welding flux backing and copper lining forms, and the liner solder flux is powdery before solidifying, and is close to workpiece 36 back sides; Make back of weld force to be shaped after heat fused is solidified, solder flux is the solder flux of the ultralow hydrogen environmental protection of high tenacity of nanometer coating, carries out submerged arc welding in the workpiece front; Obtain the weld seam of one side welding with back formation; Welded and high efficient slab or long slab can be eliminated defectives such as back side motlten metal outflow, seaming, the size of control back bead; Reinforcement particularly; Can use big electric current, less for the excursion requirement of groove precision and welding condition, thus realize the high-quality and efficient welding of high tenacity;

The digital control welding manner of said advanced person is all to adopt digital power at source of welding current I, source of welding current II and field power supply; Wire feed system adopts under the condition of electromagnetic direct-drive servomotor zero transmission; Whole welding system and welding procedure control all are advanced digital control models; Have remote monitoring, remote control and data transmission capabilities; The close-loop control mode of realizing quick response, even running, timely adjustment carries out omnibearing automatic control to each link of whole welding process, guarantees to obtain high-quality welded joint.

Three. specific embodiment:

Following embodiment implements according to welding method provided by the invention and equipment.

Example 1: electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper lining submerged arc welding thickness of slab is the E grade steel plate peculiar to vessel of 25mm; Joint adopts Y type groove, and fit-up gap 1mm, joint end face adopt machining smooth smooth; The greasy dirt and the moisture of preweld cleaning joint end face; And dry, back of weld adopts NSH-55E solder flux, flux copper-gasket single face welding and double face shaping technology; Adopt welding wire I to feel secure and weld and cover welding, its direct current welding current is 1200A, and exciting current is 20A, and field frequency is 20Hz, and welding wire II is 850A for the direct current welding current, gage of wire 4mm, speed of welding 1.5m/min.

During actual welding; According to different welding technology, quality of parent material, welding material and joint form etc.; Adopt buried arc welding method provided by the invention and equipment; Should take all factors into consideration the rational Match of various welding conditions, and main technologic parameters is optimized, can guarantee the enforcement of efficient, high-quality, low cost new submerged arc welding process.

Explanation is at last; Above embodiment is only unrestricted in order to technical scheme of the present invention to be described; Although with reference to preferred embodiment the present invention is specified, those of ordinary skill in the art should be appreciated that and can make amendment or be equal to replacement technical scheme of the present invention; And not breaking away from the aim and the scope of technical scheme of the present invention, it all should be encompassed in the claim scope of the present invention.

Claims (6)

1. an electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device is characterized in that: comprise wire feed system, the source of welding current, magnetic field power supply, flux copper-gasket system, torch system, electromagnetism hybrid system, digital control system;

Said wire feed system is that rotating shaft and the main wire feed rolls I (5) of the electromagnetic direct-drive rotating servo motor I (1) of welding wire I (33) becomes one; The two-pack that is made up of the directive wheel I (7) that is arranged in the bottom and main wire feed rolls I (5) is to accomplishing wire feed; Rotating shaft and the main wire feed rolls II (10) of the electromagnetic direct-drive rotating servo motor II (2) of welding wire II (34) become one, and the two-pack that is made up of the directive wheel II (6) that is arranged in top and main wire feed rolls II (10) is to accomplishing wire feed;

Said torch system comprises eccentric ignition tip I and eccentric ignition tip II, and eccentric ignition tip I is made up of the first half I (19) and the latter half I (20), and eccentric ignition tip II is made up of the first half II (21) and the latter half II (22);

Said electromagnetism hybrid system comprises taper magnet exciting coil (28), side plate (27), cover plate (25), following water inlet (32), upper water-out mouth (26), winding wire mouth (29); The nozzle of electromagnetism hybrid system and torch system (31), water-cooling system become one; Add the electromagnetic field effect welding region through the field power supply generation; The electromagnetism blow in the welding process is eliminated in control welding arc and molten bath, improves the joint total quality of welding;

Said flux copper-gasket system comprises inflated hose (40), copper lining (38), liner solder flux (39); For being positioned over the vapour-pressure type flux copper-gasket system of back of weld; It is the uniform liner solder flux of spreading thickness on copper lining; And feed tracheae with compressed air, be attached to the copper lining that applies good solder flux with certain pressure the back side of weld seam.

2. electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device according to claim 1; It is characterized in that: the directive wheel II (6) of said wire feed system is arranged in main wire feed rolls I (5); Be positioned on the same main shaft I, directive wheel II (6) is connected through bearing with main shaft I, and main wire feed rolls II (10) is arranged in directive wheel I (7); Be positioned on the same main shaft II; Directive wheel I (7) is connected through bearing with main shaft II, and servomotor I (1) and servomotor II (2) are arranged above and below compact conformation;

Said welding wire I (33) and welding wire II (34) accomplish the function that welding process is filled weld metal jointly;

The gathering sill surface of said directive wheel I (7) and directive wheel II (6) is smooth, and the gathering sill surface of main wire feed rolls I (5) and main wire feed rolls II (10) is coarse decorative pattern lines, helps increasing wire feed frictional force, improves feeding stability;

Said wire feed system comprises clamp mechanism and preceding thread plate (12); It is right that wire feed rolls and corresponding with it pinch wheels constitute the wire feed wheel set; Pinch wheels makes welding wire closely contact with wire feed rolls, guarantees that welding wire can send to smoothly, and preceding thread plate (12) stretches out the guiding welding wire and penetrates the welding wire guide hole very easily.

3. electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device according to claim 1 is characterized in that: the first half I of said eccentric ignition tip I (19) is connected through internal and external threads with the latter half I (20), is convenient to dismounting and replacing; The first half I (19) has off-centre to a certain degree with the latter half I (20) when being connected, formed eccentric ignition tip, has guaranteed that welding wire I (33) contacts with the good of ignition tip I; And the first half I (19) is longer, adopts more cheap Cu alloy material, has so just saved the chromium zirconium copper material of half the costliness approximately; The latter half I (20) is shorter; Adopt electric conductivity and the good chromium zirconium copper material of wearability, be convenient to endoporus fine finishining, reach best conductive effect; Conductive clip I (23) links to each other with eccentric ignition tip I, independently for welding wire I (33) welding current is provided;

The first half II of said eccentric ignition tip II (21) is connected through internal and external threads with the latter half II (22), is convenient to dismounting and replacing, and the first half II (21) has off-centre to a certain degree with the latter half II (22) when being connected; Formed eccentric ignition tip, guaranteed that welding wire II (34) contacts with the good of ignition tip II, and the first half II (21) has been longer; Adopt more cheap Cu alloy material; So just saved the chromium zirconium copper material of half the costliness approximately, the latter half II (22) is shorter, adopts electric conductivity and the good chromium zirconium copper material of wearability; Be convenient to endoporus fine finishining; Reach best conductive effect, conductive clip II (24) links to each other with eccentric ignition tip II, independently for welding wire II (34) welding current is provided;

Eccentric ignition tip I links to each other with torch body (18) through insulation locating support I (16); Eccentric ignition tip II links to each other with torch body (18) through insulation locating support II (17); The insulation locating support I (16) and the locating support II (17) that insulate are arranged in together, mutual insulating, also mutually insulated between eccentric ignition tip I and the eccentric ignition tip II; Guaranteed that the welding current between welding wire I (33) and the welding wire II (34) is separate, do not disturbed mutually;

Conductive clip I and conductive clip II select for use brass to do material, and the heat that has a resistance during welding is less, and the brass conductive folder is convenient to processing and better economy;

Ignition tip I and ignition tip II have the transition taper hole, make intermediate location level and smooth, and the dead turning of no transition can once mounting be accomplished welding wire, and work efficiency is high;

The length of conduction aperture is longer than general conductive hole length among ignition tip I and the ignition tip II; Guaranteed the contact distance of welding wire with ignition tip; Improve electric conductivity, prevented outage, electric arc shakiness and haircuts phenomenon effectively, improved the abrasion resistance of ignition tip simultaneously; Welding wire can carry out electric preheating in advance, helps welding.

4. electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device according to claim 1; It is characterized in that: the magnet exciting coil of said electromagnetism hybrid system (28) is the taper magnet exciting coil of up big and down small structure; Big magnetic field, little periphery, generation center, peripheral little distribution adapts with the welding current center is big, forms rational electromagnetic force at welding region; Control welding arc, welding pool, Welding Metallurgy overall process form quality weld;

Said electromagnetism hybrid system provides exciting current by magnetic field power supply, and generation both forward and reverse directions alternate, positive back pulse do not wait amplitude, the weak vertical rotating excitation field of pulse of strong gap alternating polarity all around in center;

The magnet exciting coil of said electromagnetism hybrid system is immersed in the cooling medium; And insulate with cooling medium; Cooling medium gets into from the following water inlet (32) that is positioned at nozzle (31) below, flows out from the upper water-out mouth (26) of the cover plate (25) that is positioned at nozzle (31) top, guarantees that like this nozzle (31), magnet exciting coil (28) have good cooling effect; Be applicable to the big electric current welding of submerged arc, simultaneously compact conformation, simple effective, reliable operation.

5. electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper-gasket submerged arc welding device according to claim 1 is characterized in that: said copper lining system is the welding system of flux copper-gasket single face welding and double face shaping, and liner solder flux (39) directly contacts with workpiece (36) back side; Copper lining (38) is arranged under the liner solder flux (39); Under the jacking supporting role of inflated hose (40), liner solder flux (39) is close to workpiece (36) back side, the size and the reinforcement of control back bead; Use big welding current; Can form back bead, and also tolerant for its allowed band of variation of groove precision and welding condition, reliable welding quality.

6. electromagnetic direct-drive high-speed double-wire magnetic-field compound flux copper lining buried arc welding method; It is characterized in that: the high-efficiency high-quality buried arc welding method of digital control type mariages high speed electromagnetic compound flux copper-gasket single face welding and double face shaping comprises the function and the effect of mariages welded and high efficient, high-speed welding, electromagnetism composite welding, flux copper-gasket single face welding and double face shaping welded and high efficient, advanced digital control welding;

Said mariages welded and high efficient mode is under the support of electromagnetic direct-drive rotating servo motor; Machine driving link between having cancelled from the motor to the wire feed system is carried out zero transmission mode, all under the digital control pattern of electrical quantity, realizes the wire feed of quick and stable; And respond fast and feedback regulation wire feed state according to the actual welding situation; Independent mutually between the mariages, establish one's own system, can carry out the coordinated movement of various economic factors and adjusting according to the welding needs again simultaneously; Welding wire I (33) is preceding; Welding wire II (34) after front and back pattern of rows and columns, when welding wire I (33) bears the function of bottoming before the weldering, the preheating of weld seam initial stage and postwelding capping, the direct current welding current is provided by source of welding current I; Welding wire II (34) provides welding current by source of welding current II; The common function of filling weld seam of accomplishing realizes bottoming, preheating, capping, the one step completed welded and high efficient of joint filling, can high efficiency accomplish thick plates; Perhaps, be arranged side by side the common function of filling weld seam of accomplishing, the welded and high efficient of realization bottoming, preheating, capping, joint filling at welding wire I (33) and welding wire II (34);

Said high-speed welding mode is under the support of mariages, big electric current, high speed wire feed, to realize high-speed welding, and mariages is not only independent but also cooperate, and can set wire feed rate respectively; Realize the combined type wire feeding mode, and carry out the adjusting of single welding wire feeding speed, realize the high-speed double-wire welding process based on welding sequence; The wire feed rate of welding wire I and welding wire II cooperatively interacts and welds; High-speed welding speed is 0.6m/min-5m/min, and welding current is 400-1200A, and gage of wire is 1.2mm-6.4mm;

Said electromagnetism composite welding mode is under the support of taper magnet exciting coil (28), field power supply, forms to dredge in close outward, the both forward and reverse directions Variable Polarity, do not wait vertical rotating excitation field of amplitude, can eliminate arc blow or attraction under welding wire I direct current+welding wire II direct current combination condition; Enlarge the electric arc area simultaneously, the rotation of control welding arc need not to swing the not fusion that just can eliminate groove or weld edge; And the metallurgical process of setting of control welding pool and weld seam fully stirs welding pool, the crystalline condition of control weld metal; Impel the weld grain refinement, reduce chemical inhomogeneities, reduce the sensitiveness of pore; Reduce pore, slag inclusion, undercut defective, improve the toughness plasticity and the erosion-resisting ability of weld seam, form quality weld; Electromagnetism composite welding exciting current 10-50A, Variable Polarity excitation frequency 1-25Hz, dutycycle 30%-70%; Luffing is than 10%-50%, and interior external diameter magnetic field intensity is than being 20%-60%;

The advantage that said flux copper-gasket single face welding and double face shaping welded and high efficient mode has fully utilized liner solder flux and copper lining forms, and the liner solder flux is powdery before solidifying, and is close to workpiece (36) back side; After solidifying, heat fused make back of weld force to be shaped; Carry out submerged arc welding in the workpiece front, solder flux is the solder flux of the ultralow hydrogen environmental protection of high tenacity of nanometer coating, obtains the weld seam of one side welding with back formation; Welded and high efficient slab or long slab; Can eliminate back side motlten metal outflow, seaming defective, the size and the reinforcement of control back bead can use big electric current; Excursion requirement for groove precision and welding condition is less, thereby realizes the high-quality and efficient welding of high tenacity;

The digital control welding manner of said advanced person is all to adopt digital power at source of welding current I, source of welding current II and field power supply; Wire feed system adopts under the condition of electromagnetic direct-drive servomotor zero transmission; Whole welding system and welding procedure control all are advanced digital control models; Have remote monitoring, remote control and data transmission capabilities; The close-loop control mode of realizing quick response, even running, timely adjustment carries out omnibearing automatic control to each link of whole welding process, guarantees to obtain high-quality welded joint.

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