CN110497061A - Automatic Welding Device and Method for Circumferential Seam of Pile Foundation Acoustic Tube - Google Patents

Abstract

The invention discloses an automatic welding device and method for the circular seam of a pile foundation acoustic measuring pipe. The front is equipped with a height-adjustable carrier, and the left side of the carrier is provided with a feeding system, and the inside of the box is installed with a driving mechanism for driving the rotation of the pneumatic chuck and a counter for recording the rotation parameters of the chuck . The device can not only solve the problem of poor welding quality of the current manual welding machine, but also greatly increase the welding speed, reduce the waste of welding materials, and effectively reduce the labor intensity of workers.

Description

Automatic Welding Device and Method for Circumferential Seam of Pile Foundation Acoustic Tube

technical field

The invention relates to the field of welding technology, in particular to an automatic welding device and method for a circular seam of a pile foundation acoustic measuring pipe.

Background technique

The pile foundation acoustic tube is the channel through which the probe enters the interior of the pile body when the cast-in-situ pile is subjected to ultrasonic testing. It is an important part of the ultrasonic testing system for cast-in-situ piles. In the prior art, the diameter and thickness of steel pipes used for welding acoustic tubes have various types, which requires frequent replacement of suitable fixtures during welding, which is time-consuming and labor-intensive, which seriously affects the welding efficiency of acoustic tubes. In addition, the welding of existing acoustic tubes is mostly manual welding. Due to differences in human habits and sense of responsibility, different workers manually rotate the steel pipes at different speeds, frequencies, and habits of operating welding torches, resulting in unstable weld quality. The ex-factory quality of the products varies greatly, and there are many safety hazards in the process of use.

Contents of the invention

In view of the above problems, the present invention provides an automatic welding device and method for the circular seam of a pile foundation acoustic measuring tube. The device can not only solve the problem of poor welding quality of the current manual welding machine, but also greatly increase the welding speed and reduce the waste of welding materials. Effectively reduce the labor intensity of workers.

The automatic welding device for pile foundation acoustic pipe girth seam includes a box body, a pneumatic chuck is installed in front of the box body, a pneumatic welding torch is arranged above the pneumatic chuck, and a height-adjustable carrier is arranged in front of the pneumatic chuck. A material rack, the left side of the material rack is provided with a feeding system, and the inside of the box is installed with a driving mechanism for driving the rotation of the pneumatic chuck and a counter for recording the rotation parameters of the chuck.

Preferably, the driving mechanism includes a motor, the motor is connected to a gearbox, the gearbox is connected to a gear transmission system, and the gear transmission system is connected to the pneumatic chuck.

Preferably, the loading frame includes a frame body, a support frame is installed above the frame body, the installation height of the support frame on the frame body is adjustable, and the side of the support frame is installed for unloading. first cylinder.

Preferably, the feeding system includes a feeding rack, the upper plane of the feeding rack is an inclined plane, the end of the feeding rack close to the loading rack is provided with a material stopper, and the side of the feeding rack is installed usefully The second cylinder for feeding.

Preferably, a support plate is installed on the execution ends of the first cylinder and the second cylinder, and the upper plane of the support plate is set in a slope shape.

Preferably, a control system is also arranged in the box, and an operation panel is arranged on one side of the box.

The present invention also discloses a method for welding the pile foundation acoustic tube by using the above-mentioned welding device, specifically as follows:

Step 1, adjust the height of the support frame so that the center of the acoustic tube blank on the support frame is coaxial with the center of the pneumatic chuck;

Step 2, start the second cylinder to realize feeding.

Step 3, start the pneumatic chuck, and clamp the joint of the acoustic tube;

Step 4, start the pneumatic welding torch to weld the acoustic tube blank and joint, and at the same time, the motor drives the pneumatic chuck to rotate;

Step 5: After the pneumatic chuck rotates for one week, the motor stops, the pneumatic welding torch stops the welding action, the pneumatic chuck is released, and the first cylinder moves to realize unloading.

Step 6, repeat the above steps 1 to 5 until all the acoustic tubes are welded.

Beneficial effects of the present invention:

(1) The device can maximize the production efficiency of bridge pile foundation acoustic tubes, reduce the labor load of workers, solve the problems of multiple types of acoustic tube joints and long time-consuming replacement of fixtures, and at the same time control the welding quality of pipe joints. Reduce dependence on the skill level of welding workers.

(2) Using a multi-functional pneumatic chuck, when processing different types of pile foundation acoustic tubes, only need to replace or adjust the stroke of the chuck to realize the clamping operation of other types of joints, which improves the production efficiency.

(3) The automatic loading and unloading device saves labor, improves coaxial alignment accuracy, and improves welding quality.

Description of drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only These are some embodiments of the present application. Those skilled in the art can also obtain other drawings based on these drawings without creative work.

Fig. 1 is the front view of the present invention;

Fig. 2 is the left view of the present invention;

Figure 3 is a view of the operation panel;

Fig. 4 is a structural diagram of the pneumatic chuck;

In the figure: 1 pneumatic chuck, 2 welding gun bracket, 3 welding gun bracket cylinder, 4 loading and unloading handle, 5 gear transmission system, 8 control system, 9 motor, 10 box, 11 gearbox, 12 counter, 13 operation panel Display screen, 14 infinitely variable speed knob, 15 host power-on button, 16 host power-off button, 17 welding gun bracket up and down adjustment buttons, 18 welding gun bracket front and rear adjustment buttons, 19 pneumatic chuck clamping button, 20 pneumatic chuck release button, 21 Welding start button, 22 Welding stop button.

(1) Inlet air pipe, (2) Gas distribution switch, (3) Exhaust port, (4) Right air intake channel, (5) Left air intake channel, (10) Piston, (11) Tie rod, (12 ) spindle, (13) short arm, (14) jaw, (15) long arm.

Detailed ways

The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, not all of them. Based on the embodiments of the present application, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present application.

As shown in Figures 1-3, the present invention installs a set of motor 9 controlled by PLC on the basis of the original electric welding machine, and one end of the motor 9 is connected to a gearbox 11, and the gearbox 11 is connected to the gear transmission system 5, and the gear transmission system 5 Drive the pneumatic chuck 1 to rotate, and install a counter 12 between the pneumatic chuck 1 and the motor 9. Whenever the pneumatic chuck 1 rotates once, the motor 9 stops rotating, the pneumatic chuck 1 is released, and the operator takes it out and welds it. The pile foundation acoustic tube is put into the joint of the next acoustic tube, the equipment automatically clamps the joint, presses the welding start button 21, and welds the next acoustic tube. Pneumatic chuck 1 front is equipped with frame body 25, and frame body 25 top is equipped with material rack 23, and the mounting height of material frame 23 on frame body 25 is adjustable, and is installed on the material frame 23 side and is used for unloading the first. A cylinder 24, the execution end of the first cylinder 24 is equipped with a supporting plate, the side of the supporting plate is a triangular corner plate, the upper plane of the supporting plate is set in a slope shape, after the acoustic tube and the acoustic tube joint are welded, The claw of pneumatic chuck 1 unclamps, and the first cylinder 24 rises, and the supporting plate at the end of the cylinder pushes the acoustic measuring tube into 28 li of storage hopper. The acoustic tube blank to be welded is placed on the loading rack 26 on the side of the frame body 25. The upper plane of the loading rack 26 is an inclined plane. The second cylinder 27 for feeding is installed on the side of the material rack 26. After the acoustic tube is welded and pushed to the storage hopper 28 by the first cylinder 24, the second cylinder 27 rises, and the supporting plate at the end of the cylinder will hold the acoustic tube. The blank is pushed to the bracket 23, and the next step of welding is continued.

When it is necessary to weld acoustic tubes with different diameters and wall thicknesses, adjust the height of the support frame 23 on the frame body 25 to realize that the axis of the acoustic tube blank on the support frame 23 is coaxial with the pneumatic chuck 1 .

The equipment is provided with a stepless speed change knob 14 which can freely adjust the rotation speed, and the welding speed can be freely adjusted according to the thickness of the welding workpiece and welding parameters.

The device mainly consists of the following parts:

One set of servo motor, one set of integrated circuit board, one set of pneumatic chuck, four sets of cylinders, one set of counter, one set of circular seam automatic welding operation panel. The integrated circuit board is the control hub of the equipment, and the specific operation is indicated by the operation panel. When the equipment is working normally, put the pile foundation acoustic pipe joint to be welded on the pneumatic chuck, and press the clamping button 19 of the pneumatic chuck. , the cylinder rod stretches out, pushes the jaws of the pneumatic chuck, and the jaws shrink in the specified direction, thereby clamping the joint. Butt the raw material of the acoustic tube with the joint, then press the welding start button 21, the carbon dioxide shielded welding machine and the servo motor run at the same time, every time the pneumatic chuck rotates once, the counter 12 records the number of welding times, and when the welding is completed for one week, The integrated circuit board feeds back the welding times recorded by the counter, and then the integrated circuit board controls the carbon dioxide protection welding machine and the servo motor to stop working, the cylinder rod is then retracted, the pneumatic chuck is opened, and the welding is completed.

Compared with most of the current pile foundation acoustic tube welding equipment, this device has seven main advantages. First, the equipment is easy to operate, and it is more intuitive and convenient to control through the operation surface. Second, the welding quality has been greatly improved, and the degree of automation is higher, which makes the welding quality of the acoustic tube better and more uniform than that of manual welding. Third, it can weld various types of pile foundation acoustic tubes, which reduces the time for frequent chuck replacement and greatly improves welding efficiency. Fourth, more materials can be saved, and auxiliary materials such as welding wire and carbon dioxide will not be wasted. Fifth, it is more convenient to adjust the welding parameters. When welding pile foundation acoustic tubes of different thicknesses, the corresponding welding current and voltage need to be adjusted according to the thickness. Change to the corresponding welding parameters. Sixth, the loading and unloading realizes pneumatic control, and the counting is controlled by the program, which reduces the labor intensity of workers. Seventh, the investment of special operators is reduced, the production cost is reduced, and the economic benefit is improved.

Under the same inspection conditions, the pass rate of the welding quality of the device is 99%, which is 20% higher than that of traditional excellent welders, and the welding appearance is uniform and smooth, which reduces the number of times of rework and effectively improves the welding quality. . In terms of welding speed, the device welds about 1,200 times per day (8 hours), which is about 10,800 meters based on an average of 9 meters per acoustic tube, which is nearly 40% more than traditional manual welding.

Check the condition of the device before welding. If there is no abnormal situation, turn on the power supply, press the power button (15) on the main machine on the operation panel, the equipment will start, check the operation of the equipment, and perform welding work after being correct.

When welding, put the joint to be welded into the pneumatic chuck 1, step on the clamping button and the cylinder of the pneumatic chuck shrinks, and the pneumatic chuck 1 is clamped. After confirming the clamping, press the welding button 21, and the welding torch holder cylinder 3 stretches out , to drive the welding torch bracket 2 and the welding torch nozzle to reach the optimal welding range, and start welding, while the motor 9 rotates, and the pneumatic chuck 1 is driven to rotate through the gearbox 11 and the gear transmission system 5. After the equipment welds itself for one week, the counter 12 transmits the information To the control system 8, the control system 8, according to the set program, starts the motor to stop the rotation command, the motor stops the rotation, and at the same time the pneumatic chuck cylinder receives the command to release the chuck, the pneumatic chuck is released, and the acoustic tube is manually pulled Loading and unloading handle 4, automatic loading after blanking, put into the joint, and continue to circulate the welding process.

When it is necessary to adjust the welding parameters, professional technicians can quickly adjust them on the welding operation panel, and calibrate by debugging the welding button to ensure that the welding parameters are set reasonably.

As shown in Figure 4, the working principle of the starting chuck is as follows: the left end of the main shaft (12) fixes a cylinder (9) with a flange, the compressed air passes through the inlet air pipe (1), the air distribution switch (2), and the left air intake channel (5) Enter the left side of the cylinder. The piston (10) moves to the left, driving the pull rod (11) and the long arm (15) of the crankshaft to move, and the short arm (13) makes the claw (14) clamp the workpiece, and the gas on the left side of the cylinder moves along the left The side air passage (4), the gas distribution switch (2), and the exhaust port (3) are discharged. If the handle of the air distribution switch is turned to connect the inlet air pipe (1) to the right pipe (4) and the exhaust port (3) to the left pipe (5), the compressed air will flow in the opposite direction and the claws will be released automatically. open.

The present invention solves the following technical problems:

(1) Adopt the principle of human-computer interaction design, comprehensively consider the comfort of people when working, the convenience of loading and unloading, the advance and retreat speed of welding torch, the quick clamping of pipe joints, the rotation and swing of welded parts, and the operation control The interactive coordination of the panel, manual button and foot button.

(2) Solve the problems of different diameters and thicknesses of steel pipes, different types of pipe joints, frequent replacement of fixtures, and long time-consuming problems. In order to reduce the frequency of fixture replacement, this device adopts a new multi-functional pneumatic chuck, which can realize fast clamping when welding different types of acoustic tubes, which improves the production efficiency of the product.

(3) Solve the problem of manually turning the steel pipe and manually operating the welding torch, resulting in unstable weld quality. From welding torch drop-spot welding-restarting arc-rotation-welding-arc ending-welding torch lifting, all automatic operations are realized, precisely controlled by PLC, which reduces the welding technical requirements for workers. Workers only need to know how to operate The equipment is enough, no need to designate special operators to operate, and the welding quality is stable, the weld seam is uniform and beautiful, ensuring that the weld seam passes the hydraulic test at one time, no leakage occurs, and rework is reduced.

(4) Solve the problem of manual loading and unloading. Loading and unloading are all controlled by pneumatics, which reduces the labor intensity of workers. The counting is controlled by PLC, which reduces the error of manual counting and improves work efficiency.

The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the application. Therefore, the present application will not be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims (7)

1. pile foundation sound ranging pipes circumferential weld automatic soldering device, which is characterized in that including cabinet, be equipped with pneumatic clamping in front of the cabinet Disk, the air spider top are configured with pneumatic welding gun, and height-adjustable loading frame is configured in front of the air spider, described Feeding system is provided on the left of loading frame, the box house is equipped with driving mechanism and use for driving air spider to rotate In the counter for recording chuck rotational parameters.

2. pile foundation sound ranging pipes circumferential weld automatic soldering device according to claim 1, which is characterized in that the driving mechanism packet Motor is included, the motor is connected with gearbox, and the gearbox is connected with gear train assembly, the gear train assembly and gas Dynamic chuck connection.

3. pile foundation sound ranging pipes circumferential weld automatic soldering device according to claim 1, which is characterized in that the loading frame includes Frame body, the frame body top are equipped with material supporting rack, and mounting height of the material supporting rack on frame body is adjustable, the material supporting rack side The first cylinder for discharging is installed.

4. pile foundation sound ranging pipes circumferential weld automatic soldering device according to claim 3, which is characterized in that the feeding system packet Stock shelf is included, the upper plane of the stock shelf is clinoplain, and the stock shelf is provided with material blocking block close to one end of loading frame, The stock shelf side is equipped with the second cylinder for feeding.

5. pile foundation sound ranging pipes circumferential weld automatic soldering device according to claim 4, which is characterized in that first cylinder and The actuating station of second cylinder is mounted on retainer plate, and the upper plane of the retainer plate is set as slope shape.

6. pile foundation sound ranging pipes circumferential weld automatic soldering device according to claim 1, which is characterized in that also set in the cabinet It is equipped with control system, cabinet side is provided with operation panel.

What 7. a kind of pile foundation sound ranging pipes circumferential weld automatic soldering device using described in claim 5 welded pile foundation sound ranging pipes Method, specific as follows:

Step 1, material supporting rack height is adjusted, the center of sound detecting pipe blank material and air spider central coaxial on material supporting rack are made；

Step 2, start the second cylinder, realize feeding；

Step 3, start air spider, by the joint-clamping of sound detecting pipe；

Step 4, start pneumatic welding gun to weld sound detecting pipe blank material and connector, while motor driven air spider rotates；

Step 5, motor stalls, pneumatic welding gun stop welding movement after a week for air spider rotation, and air spider unclamps, the One cylinder movement realizes discharging；

Step 6,1 is repeated the above steps to step 5, until the welding of all sound detecting pipes finishes.