CN106021849A - Calculation and control method for welding material actual consumption - Google Patents
Calculation and control method for welding material actual consumption Download PDFInfo
- Publication number
- CN106021849A CN106021849A CN201610290053.0A CN201610290053A CN106021849A CN 106021849 A CN106021849 A CN 106021849A CN 201610290053 A CN201610290053 A CN 201610290053A CN 106021849 A CN106021849 A CN 106021849A
- Authority
- CN
- China
- Prior art keywords
- welding
- welding material
- redundancy
- actual
- weld
- 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
Classifications
-
- G—PHYSICS
- G16—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS
- G16Z—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS, NOT OTHERWISE PROVIDED FOR
- G16Z99/00—Subject matter not provided for in other main groups of this subclass
Landscapes
- General Factory Administration (AREA)
Abstract
The invention discloses a calculation and control method for the welding material actual consumption. The method includes the following steps: a, acquiring various actual welding redundancy average values of different joint types through a field measurement method; b, calculating the welding material actual consumption of each weld joint, and a calculation formula: the welding material actual consumption= the sectional area of the weld joint*the length of the weld joint* the metal density/the melting efficiency of a welding material, wherein the sectional area of the weld joint is calculated by considering the actual welding redundancy average values of the step a, and the melting efficiency of the welding material is measured through tests; and c, clearing a single weld joint and multi-weld joint, performing like term combining on all the weld joints of the whole member or unit to form welding material details, allowing the welding material details to correspond to construction units one-to-one, and performing quota budget before use and performing checking after use. The calculation and control method can remarkably reduce the welding material actual consumption and reduce the production cost of an enterprise.
Description
Technical field
The present invention relates to calculating and the control method of a kind of welding material actual amount, boats and ships and ocean work can be widely used in
The industries such as journey, steel construction, boiler, pressure vessel, are particularly well-suited to structure is complicated, materials'use amount is big boats and ships and ocean work
Journey construction applications.
Background technology
Modern age shipbuilding technology development experience multiple stages, from the fifties, hull construction uses welding to instead of riveting, builds
Mode of making is built by the segmentation module that develops into the most in bulk, and welding method also expands to submerged-arc welding, gas shielded arc welding, manual arc
Weldering, argon arc welding etc., wherein, welding material is the necessary support of each stage various method.At present, domestic each big ship enterprise
Welding material usage amount the most different, account for 2.5% the 10% of Ship Structure weight, and Japan's ship enterprise to be only 2% left
The right side, gets rid of beyond design factor, is more the waste in production process and welding redundancy.With common on current market of ship
As a example by 180000 tons of bulk freighters, its weight of ship is about 22000 tons, calculates by 2.5%, then needs 550 tons of welding materials, phase
In the case of Tong, Japan's ship enterprise has only to 440 tons of welding materials, and single ship construction cost at least can save 1,000,000 yuan, with
Time, recessive save cost of labor, to produce the expenses such as power consumption the most considerable.
Ship enterprise both domestic and external is all controlling the consumption of welding material, one by the way of different, mainly passes through administration
Means, reduce the waste during using, but do not solve to weld redundancy, as long as also implying that welding material is welded to weld seam
In and do not abandon and just can accept.Its two, by design directly calculating segmentation theoretical amount, then by placing coefficient
Mode gives the actual amount of segmentation.But, which maximum has a problem in that design-calculated theoretical amount is by any side
Formula or means are impossible to realize, and the coefficient placed is difficult to determine, the accuracy providing actual amount is the highest, loses control
The value of reference processed, it addition, segmentation experienced by multiple working procedure, multiple unit in charge of construction during actual production, is difficult to distinguish
And management.In conjunction with above two mode, the waste in production process easily solves, and accounts for smaller；By welder in welding process
The impact of the factors such as operation level, assembly precision, weld reinforcement and the welding redundancy accounting that causes is relatively big, directly determine welding
The usage quantity of material.How to obtain the component of different production phase or organize accurate data and the detail of vertical unit actual amount, real
The control of existing process and managerial aptitude reduce the usage amount of welding material, reduce the production cost of enterprise.
Summary of the invention
Based on above-mentioned technical problem, the present invention provides calculating and the control method of a kind of welding material actual amount.
The adopted technical solution is that:
The calculating of a kind of welding material actual amount and control method, comprise the following steps:
A obtains all kinds of actual welding redundancy mean values of different joint form by the means of in-site measurement；
B calculates the welding material actual amount of per pass weld seam, and computing formula is as follows:
The deposition efficiency of the density ÷ welding material of the sectional area × fusion length × metal of welding material actual amount=weld seam, its
In, the sectional area of weld seam welds redundancy mean values by joint design with the actual measurement of step a and considers calculating acquisition, welds material
The deposition efficiency of material passes through test determination；
All weld seams merging similar terms of the clear and definite single-pass welding of c or multiple-pass weld, the most whole component or unit collect and are organized into weldering
Connect material specification, accomplish the detailed one_to_one corresponding with unit in charge of construction of welding material, after the norm for detailed estimates before using and use
Inspection examination.
In above-mentioned steps, described welding redundancy is the part beyond design size, welding redundancy content include: leg, reinforcement,
Gap, flanging and carbon plane.
In above-mentioned steps, by progressively reduce welding redundant quantities to target value, gradually reduce the quota of welding material, by force
Unit in charge of construction processed improves operant skill, reduces process waste.
The method have the benefit that:
1, the welding material actual amount of the vertical unit of per pass weld seam, each component or group can directly and be accurately calculated, it is thus achieved that
Consumption is detailed accurately, for realizing the management and control offer basic data that becomes more meticulous.
2, it is obtained in that the welding material corresponding to unit in charge of construction's receiver amount is detailed, it is achieved quota management, and is capable of operation
Between supervision and management, reaction building course present in problem.
3, can significantly reduce welding material consumption, reduce the production cost of enterprise, meanwhile, the artificial one-tenth of stealth can be reduced
Basis, energy loss etc..
Accompanying drawing explanation
The invention will be further described with detailed description of the invention below in conjunction with the accompanying drawings:
Fig. 1 is angle welding schematic cross-section；
Fig. 2 is butt weld schematic cross-section.
Detailed description of the invention
The present invention proposes a kind of method that can directly calculate weld seam actual welding material usage, then according to the life of enterprise's design
Runoff yield collects to the welding material carrying out weld seam or member unit use, it is thus achieved that the welding material detail of its correspondence (comprises material name
The information such as title, the trade mark, specification, quantity), and using this detail as the foundation of management, it is achieved the management and control that becomes more meticulous of process, i.e.
Accomplishing that thing amount is certain, welding material is the most certain.Both can guarantee that effectiveness and the accuracy of data, can realize again the management of process with
Control, reduce the purpose of enterprise's production cost.
The calculating of a kind of welding material actual amount and control method, comprise the following steps:
A obtains all kinds of actual welding redundancy mean values of different joint form by the means of in-site measurement.
B calculates the welding material actual amount of per pass weld seam, and computing formula is as follows:
The deposition efficiency of the density ÷ welding material of the sectional area × fusion length × metal of welding material actual amount=weld seam, its
In, the sectional area of weld seam welds redundancy mean values by joint design with the actual measurement of step a and considers calculating acquisition, welds material
The deposition efficiency of material passes through test determination.
All weld seams merging similar terms of the clear and definite single-pass welding of c or multiple-pass weld, the most whole component or unit collect and are organized into weldering
Connect material specification, accomplish the detailed one_to_one corresponding with unit in charge of construction of welding material, after the norm for detailed estimates before using and use
Inspection examination.
Joint form according to design and fusion length, measure and suitably weld redundancy, calculate the actual welding material of per pass weld seam
Material consumption, specifies the information such as the welding material title of this weld seam use, the trade mark, specification, then according to scheduling of production, it is ensured that should
Road weld seam is constructed by the unit in charge of construction specified, and the thing amount that i.e. unit in charge of construction undertakes is certain, and the welding material of its correspondence is detailed with regard to one
Fixed, it is commonly called as quota.Certainly, in actual mechanical process, can give unit in charge of construction's multiple-pass weld or certain component, certain
All weld seams that unit, even certain engineering comprise, carry out collecting of various consumption with the information of welding material, provide total weldering
Connect material usage detailed, accomplish that unit in charge of construction, unit in charge of construction undertake thing amount, the one_to_one corresponding of welding material detail.As depending on
According to being managed, the inspection examination after the norm for detailed estimates before using and use, force teams and groups and contractor to improve assembling
Precision, the welding operation technical ability that improves, reduction welding redundancy, finally reduce production cost.
Unit in charge of construction, unit in charge of construction undertake thing amount, the one_to_one corresponding of welding material detail, and the thing amount that i.e. unit in charge of construction undertakes is certain,
The welding material of its correspondence is also certain, comprises the information such as the title of material, the trade mark, specification, weight.Determine that unit in charge of construction undertakes
Thing amount can be amplified to multiple-pass weld by single-pass welding, the most whole component or all weld seams of unit, simply to per pass weld seam
Result of calculation and welding material detail carry out similar terms and merge and collect, it is thus achieved that the bigger welding material of weight is detailed.
In above-mentioned steps, described welding redundancy is the part beyond design size, welding redundancy content include: leg, reinforcement,
Gap, flanging and carbon plane etc..
In above-mentioned steps, the deposition efficiency of welding material can be measured by soldering test；The sectional area of weld seam needs basis
The joint form of design and the practical skill situation of operation calculate, and main reasons is that anyone or machine weld the knot obtained
Fruit is impossible to and designs identical, and the most either large or small there are differences, and the size of difference directly determines the redundancy of welding
Amount, redundancy is the biggest, and the cost of increase is the highest, reduces welding redundancy the most as far as possible, maximum possible close to design size
Consumption can be reduced, reduce cost.But, during the calculating of actual amount, it is necessary to consider to increase certain welding redundancy
Just can meet the practical situation of execute-in-place, as the concrete amount of redundancy increased then can according to on-the-spot practical operation level determination,
And reasonably adjust according to the needs of follow-up management, the data calculating gained after adding welding redundancy can be very accurate,
The most just there is the basic data that management controls.The welding redundancy being directed to mainly comprises the following aspects:
First is the welding redundancy of filled weld leg；
Second is the welding redundancy of the generations such as butt weld root gap, reinforcement, flanging；
3rd is the welding redundancy of the generations such as the root gap of angle welding of complete penetraction and fusion in welding, flanging, leg；
4th is the welding redundancy of the generations such as the fit-up gap of angle welding of deep penetration welding, flanging, leg；
5th is the loading of welding material needed for the steel plate that carbon arc air gouging plane falls；
6th is to increase the loading of welding material needed for run-on tab, arc-extinguishing plate welding and transition；
Above-mentioned six aspects are the representative of Typical Joints form, any joint form of design, if comprise gap, leg,
The contents such as reinforcement, flanging, angle, root face, carbon plane are required for considering certain welding redundancy.
During actual control, the actual welding redundancy first measured at the construction field (site) with various terminal form is as standard, logical
Cross progressively reduce welding redundancy and compress the detailed mode of quota (i.e. by progressively reducing redundant quantities to target value, even without
Limit, close to zero, gradually reduces the quota of welding material), during forcing unit in charge of construction improve the operant skill of self, minimizing
Waste and reach reduce consumption purpose.Meanwhile, need before the welding of lower procedure unit in charge of construction to confirm what upstream process flow through
Whether component meets required precision and reports, otherwise, this unit in charge of construction need to undertake the situations such as upstream process precision is the most up to standard voluntarily and
The welding material additional quantities caused, plays the effect of supervision upstream, downstream.
The mode of such scheme, can extend, if accomplish region, unit in charge of construction, welding material, the one of welding thing amount
One is corresponding, without the change of Regional Economy, again or weld the size of thing amount, as long as can collect to the welding material corresponding to earnest amount bright
Thin and consumption is all within the comprising of this programme.
For describing computational methods and the control mode of the present invention in detail, it is explained below in conjunction with specific embodiment, but the present invention is also
It is not limited to these embodiments.
As it is shown in figure 1, steel plate 1 and steel plate 2 are assembled into filler weld, design leg 3 is assumed to be 5mm, corresponding solder side
Long-pending 31 is 12.5mm2, welding redundancy 4 is the situation such as 1mm or 2mm or 3mm, and welding redundant area 41 corresponding respectively is 5.5
mm2,12mm2,19.5mm2, the welding capacity comparing design increases by 44%, 96% respectively, and 156%. after welding terminates, actual survey
The leg of amount is usually 7mm, but, actual leg can be controlled at 5.5mm by the workman that technical merit is preferably, responsibility is stronger,
Saving 38.3% than common 7mm, therefore welding redundancy 4 just can gradually reduce as 0.5mm from 2mm, thus realizes reduction
The purpose of welding material consumption.When actual amount calculates, after directly the welding redundancy 4 set being welded 3 totals with design
Calculate, can obtain and use data accurately.As: design leg 3 is 5mm, and welding redundancy 4 is 1mm, fusion length
For 1000mm, the density of metal is 7.85g/cm3, the deposition efficiency of the welding material of mensuration is 82%, then needed for this weld seam
Welding material weight=(5+1)2/ 2*1000/1000*7.85=141.3g
As in figure 2 it is shown, after steel plate 5 docks with steel plate 6 assembling, the actual numerical value in measurement gap 11 that can be clear and definite, set with it
The standard clearance of meter contrasts, it is thus achieved that can reflect the gap redundancy of on-the-spot actual state, after welding terminates, just can measure
Face reinforcement 7, root reinforcement 8, front flanging 9, the actual numerical value of back side flanging 10, take above-mentioned numerical value repetitive measurement respectively
Meansigma methods just can reflect the long-run average of job site, the most directly carries out the calculating of actual amount, calculates and control mode and figure
Filler weld shown in 1 is similar.
Fig. 1, Fig. 2 are the representative of joint form, and in order to describe the mode calculating with controlling intuitively, other is any type of
Joint form, it is only necessary to according to actual joint situation, reasonable contemplation gap, angle, flanging, reinforcement, leg, carbon plane
Redundancy etc. factor, it is possible to directly calculate the actual welding material usage obtaining weld seam, and then it is detailed to obtain welding material consumption,
Within any calculating accommodation similar with foregoing is included in the computer capacity of this programme.
During actual control, can by Fig. 1 filler weld calculate what detailed corresponding thing amount be transferred to uniquely to specify
Unit in charge of construction constructs, accomplish that thing amount that unit in charge of construction, unit in charge of construction undertake, welding material actual amount are detailed one a pair
Should, it is possible to realize the budget control before welding, the examination after welding.
Although the most more employing filler weld, butt weld, joint form, gap, angle, flanging, reinforcement, weldering
The terms such as angle, carbon plane, welding redundancy, but it is not precluded from using the probability of other term.These terms are used to be only used to
Describe and explain the essence of the present invention more easily；Being construed as any additional restriction is all and spirit phase of the present invention
Run counter to.
Claims (3)
1. the calculating of a welding material actual amount and control method, it is characterised in that comprise the following steps:
A obtains all kinds of actual welding redundancy mean values of different joint form by the means of in-site measurement；
B calculates the welding material actual amount of per pass weld seam, and computing formula is as follows:
The deposition efficiency of the density ÷ welding material of the sectional area × fusion length × metal of welding material actual amount=weld seam, wherein, weldering
The sectional area stitched welds redundancy mean values by joint design with the actual measurement of step a and considers calculating acquisition, melting of welding material
Deposited efficiency passes through test determination；
All weld seams merging similar terms of the clear and definite single-pass welding of c or multiple-pass weld, the most whole component or unit collect and are organized into welding material
Expect detail, accomplish the detailed one_to_one corresponding with unit in charge of construction of welding material, the norm for detailed estimates before using and the inspection after use
Examination.
The calculating of a kind of welding material actual amount the most according to claim 1 and control method, it is characterised in that: described welding
Redundancy is the part beyond design size, and the content of welding redundancy includes: leg, reinforcement, gap, flanging and carbon plane.
The calculating of a kind of welding material actual amount the most according to claim 1 and control method, it is characterised in that: by progressively
Reduce welding redundant quantities to target value, gradually reduce the quota of welding material, force unit in charge of construction improve operant skill,
Minimizing process is wasted.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201610290053.0A CN106021849A (en) | 2016-05-03 | 2016-05-03 | Calculation and control method for welding material actual consumption |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201610290053.0A CN106021849A (en) | 2016-05-03 | 2016-05-03 | Calculation and control method for welding material actual consumption |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN106021849A true CN106021849A (en) | 2016-10-12 |
Family
ID=57081630
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201610290053.0A Pending CN106021849A (en) | 2016-05-03 | 2016-05-03 | Calculation and control method for welding material actual consumption |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN106021849A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106991517A (en) * | 2017-02-08 | 2017-07-28 | 浙江工业大学 | A kind of welding material use quantity computational methods |
| CN108897983A (en) * | 2018-08-07 | 2018-11-27 | 重庆工业职业技术学院 | A kind of calculating and control method of computer based welding material actual amount |
| CN109376411A (en) * | 2018-09-30 | 2019-02-22 | 武昌船舶重工集团有限公司 | A kind of welding quantity statistics method and system |
| CN111611526A (en) * | 2020-05-29 | 2020-09-01 | 广船国际有限公司 | Method for calculating welding material amount used by ship model |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1904874A (en) * | 2006-07-25 | 2007-01-31 | 四川东风电机厂有限公司 | Computing device for welding material use quantity |
| CN103357991A (en) * | 2013-06-28 | 2013-10-23 | 江苏中核利柏特股份有限公司 | Horizontal fixed welding technology for aluminium process pipeline |
| CN105045939A (en) * | 2014-03-07 | 2015-11-11 | 泰州学院 | Welding line filling welding material consumption layering calculation method |
| CN105364299A (en) * | 2015-12-15 | 2016-03-02 | 中国铁道科学研究院金属及化学研究所 | Bainitic steel thermit welding material and welding technology |
-
2016
- 2016-05-03 CN CN201610290053.0A patent/CN106021849A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1904874A (en) * | 2006-07-25 | 2007-01-31 | 四川东风电机厂有限公司 | Computing device for welding material use quantity |
| CN103357991A (en) * | 2013-06-28 | 2013-10-23 | 江苏中核利柏特股份有限公司 | Horizontal fixed welding technology for aluminium process pipeline |
| CN105045939A (en) * | 2014-03-07 | 2015-11-11 | 泰州学院 | Welding line filling welding material consumption layering calculation method |
| CN105364299A (en) * | 2015-12-15 | 2016-03-02 | 中国铁道科学研究院金属及化学研究所 | Bainitic steel thermit welding material and welding technology |
Non-Patent Citations (1)
| Title |
|---|
| 马志才等: "金属粉芯型气体保护焊丝在管道焊接中的应用", 《安装》 * |
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106991517A (en) * | 2017-02-08 | 2017-07-28 | 浙江工业大学 | A kind of welding material use quantity computational methods |
| CN106991517B (en) * | 2017-02-08 | 2020-01-31 | 浙江工业大学 | welding material consumption calculation method |
| CN108897983A (en) * | 2018-08-07 | 2018-11-27 | 重庆工业职业技术学院 | A kind of calculating and control method of computer based welding material actual amount |
| CN108897983B (en) * | 2018-08-07 | 2021-12-03 | 重庆工业职业技术学院 | Computer-based method for calculating and controlling actual consumption of welding material |
| CN109376411A (en) * | 2018-09-30 | 2019-02-22 | 武昌船舶重工集团有限公司 | A kind of welding quantity statistics method and system |
| CN109376411B (en) * | 2018-09-30 | 2022-09-23 | 武昌船舶重工集团有限公司 | Welding mass statistical method and system |
| CN111611526A (en) * | 2020-05-29 | 2020-09-01 | 广船国际有限公司 | Method for calculating welding material amount used by ship model |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN106021849A (en) | Calculation and control method for welding material actual consumption | |
| Stenberg et al. | Quality control and assurance in fabrication of welded structures subjected to fatigue loading | |
| CN109604767B (en) | Intelligent welding control system and method for thick plate narrow gap GMA robot | |
| CN102728932B (en) | Method and device for automatically optimizing electric-arc welding process parameters | |
| Caccese et al. | Effect of weld geometric profile on fatigue life of cruciform welds made by laser/GMAW processes | |
| EP2427299B1 (en) | Method for manufacturing a door frame, welding arrangement and structure of a door frame | |
| KR20140000286A (en) | Welding-type system and method of calculating a cost of a welding operation, with cost calculator | |
| CN102788745B (en) | Welding seam corrosion resistance test evaluation method | |
| CN103586593A (en) | Method for predicting dissimilar steel welding cold cracking sensitivity | |
| CN104227182A (en) | Process for molding I-steel main welding seam non-back chipping full-penetration I-level component | |
| CN102514687A (en) | Ship block closing method | |
| CN103080384A (en) | Electrochemical anodes having friction stir welded joints and methods of manufacturing such anodes | |
| Healy et al. | Extrapolation procedures for determining SCFs in mid-surface tubular joint models | |
| CN205998094U (en) | A kind of two-sided welding structure of U rib of putting more energy into of orthotropic stiffener | |
| Melaku et al. | Evaluation of welded joints of vertical stiffener to web under fatigue load by hotspot stress method | |
| CN106314700A (en) | Ocean platform, connecting bracket plate, and design method of connecting bracket plate | |
| Ocel et al. | Optimization of rib-to-deck welds for steel orthotropic bridge decks | |
| Ericson Öberg et al. | The influence of correct transfer of weld information on production cost | |
| CN201449234U (en) | Measuring component of size of welding line | |
| CN208728922U (en) | A kind of laser welding apparatus being installed on robotic gun | |
| CN116198681A (en) | Ship folding method based on simulation assembly | |
| CN205037960U (en) | Body connecting device is called to truck scale | |
| Ye et al. | Static and fatigue analysis of three types of aluminium box-stiffener/web frame connections | |
| CN203642871U (en) | Steel bridge deck fatigue damage repaired welded joint deformation monitoring device | |
| Kai-liang et al. | Crack analysis of multi-plate intersection welded structure in port machinery using finite element stress calculation and acoustic emission testing |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| RJ01 | Rejection of invention patent application after publication |
Application publication date: 20161012 |
|
| RJ01 | Rejection of invention patent application after publication |