CN114273754B - Automatic welding control method - Google Patents

Automatic welding control method Download PDF

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CN114273754B
CN114273754B CN202210067367.XA CN202210067367A CN114273754B CN 114273754 B CN114273754 B CN 114273754B CN 202210067367 A CN202210067367 A CN 202210067367A CN 114273754 B CN114273754 B CN 114273754B
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welding
unit
pipeline
butt joint
joint position
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CN114273754A (en
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何江龙
李荣东
张旺
喻宗磊
舒坛
秦小省
先泽均
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CHENGDU XIONGGU JIASHI ELECTRICAL CO LTD
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CHENGDU XIONGGU JIASHI ELECTRICAL CO LTD
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Abstract

The application discloses an automatic welding control method. Through removing the welding unit, discernment pipeline butt joint position makes the welding unit be located pipeline butt joint position directly over, through this automatic control mode, has reduced the cost of labor. Initializing a welding unit, obtaining an initial position of the welding unit, scanning a butt joint position of a pipeline, obtaining scanning data, obtaining a welding gun position through the scanning data, planning welding parameters and a welding path, and controlling the welding unit to perform welding operation. The welding gun position is obtained through sensor calculation, and the welding parameters and the welding path are automatically planned through the deep learning network, so that the automation of the whole welding process is realized, the labor cost is greatly reduced, the precision error caused by manual operation is eliminated, and the welding precision is improved.

Description

Automatic welding control method
Technical Field
The application relates to the field of welding, in particular to an automatic welding control method.
Background
Along with the rapid increase of the demand of people for various resources in social technology progress, long-distance pipeline development is towards large caliber, long distance, high pressure and high steel grade, traditional manual welding and semi-automatic welding are difficult to meet the requirement of pipeline welding, the welding technology is also developed towards automatic welding, multilayer multi-pass welding is adopted, inner welding machine is adopted to perform backing welding firstly, and then outer welding machine is used to perform hot welding, filling welding and cover welding.
At present, manual control remote controllers are adopted for external welding, a welding machine is controlled to carry out single-layer welding on a groove, initial positions of all units are obtained before welding, welding parameters, the number of planned welding layers and welding paths are manually preset, and errors of manual operation may affect the planning of the welding parameters and the welding paths, so that the accuracy of subsequent welding operation is affected. The welding gun is manually aligned to the center of the groove, and after welding is finished, equipment is manually moved from the finishing point to the arcing point of the next welding layer, so that the welding mode has long training time for operators, high skill requirements and unsecured welding efficiency and precision.
Disclosure of Invention
In view of the above, the application provides an automatic welding control method, which solves the problems of high labor cost, low welding efficiency, low accuracy and low welding qualification rate by automatically controlling a welding workstation.
The application provides a control method of an automatic welding machine, which comprises the following steps:
moving the welding unit, identifying the pipeline butt joint position, judging whether the welding unit is positioned right above the pipeline butt joint position, if not, continuing to move the welding unit until the welding unit is positioned right above the pipeline butt joint position, and if so;
initializing a welding unit, determining the initial position of the welding unit, and scanning the contour of the butt joint position of the pipeline to obtain pre-scanning data;
determining the position of a welding gun according to the pre-scanning data, and planning welding parameters and welding paths;
and controlling the welding unit to perform welding operation according to the welding gun position, the welding parameters and the welding path until the welding operation is completed.
Preferably, the step of identifying the pipe butt joint position and judging whether the welding unit is located right above the pipe butt joint position includes:
based on the groove detection unit detecting the groove position of the pipeline, the welding unit is driven to move to the position above the butt joint position of the pipeline, and when the groove detection unit detects that the distance between the welding unit and the butt joint position of the pipeline in the extending direction of the pipeline is smaller than a first precision threshold value, the welding unit is finely adjusted to enable the horizontal distance between the welding unit and the butt joint position of the pipeline to be smaller than a second precision threshold value.
Preferably, the groove identification unit comprises a visible light camera module, an infrared camera module or a structured light camera module.
Preferably, the step of initializing the welding unit and determining the initial position of the welding unit includes:
the clamping unit is controlled to clamp the pipeline, whether the clamping is stable or not is judged, and if yes, the clamping unit is controlled to clamp the pipeline;
the welding unit is energized to obtain an initial position of the welding unit on the clamping unit.
Preferably, the process of obtaining the initial position of the welding unit is:
and calculating the absolute value position of the driving motor according to the multi-circle absolute value decoder of the driving motor of the welding unit, and taking the absolute value position as the initial position of the welding unit.
Preferably, the method further comprises:
and collecting the pipeline temperature of the pipeline butt joint position area, judging whether the temperature is smaller than the preset temperature, if so, heating the area through a heating coil on the clamping unit until the pipeline temperature of the area is not smaller than the preset temperature, and entering the next step.
Preferably, the step of obtaining pre-scan data includes:
and performing circumferential scanning on the pipeline butt joint position based on the initial position of the welding unit to obtain pre-scanning data of the pipeline butt joint position along the circumferential direction, wherein the pre-scanning data comprises one or more of weld joint type, groove angle, width, height, tangential surface area and misalignment amount.
Preferably, the step of determining the welding gun position, planning the welding parameters and the welding path according to the profile scanning data comprises the following steps:
based on the initial position of the welding unit and the pre-scanning data, adjusting the angle and the dry extension of the welding gun, and determining the position of the welding gun;
extracting key point coordinates of the pipeline butt joint position and morphology of the pipeline butt joint position based on the pre-scanning data;
the number of welding layers and welding beads is planned according to the shape of the butt joint position of the pipeline, and the shape of the welding seam of each welding layer and each welding bead is estimated;
generating welding parameters required by welding corresponding to the weld morphology according to each weld morphology;
and generating a welding path according to the welding parameters and the key point coordinates.
Preferably, the steps of generating the welding parameters and generating the welding paths required by the welding corresponding to the shape of the weld joint include:
inputting the welding patterns of the welding layers and each welding bead into a first neural network, and predicting welding parameters required to be used;
sending the welding parameters into a second neural network, and reversely predicting the shape of the weld;
comparing the predicted weld morphology with the weld morphology of each weld bead, judging whether a third precision threshold is met, outputting welding parameters if the third precision threshold is met, and adjusting the welding parameters and re-comparing if the third precision threshold is not met;
and inputting the welding parameters and the coordinates of the key points into a third neural network to generate a welding path.
Preferably, the process of extracting the key point coordinates of the pipeline docking position includes:
and according to the pre-scanning data, using the inflection point and the lowest point as key point coordinates in a two-dimensional coordinate system.
Preferably, the welding operation includes:
the gas sensor monitors the flow rate, the concentration and the pressure of the shielding gas in real time, and respectively judges whether any one of the flow rate, the concentration and the pressure of the shielding gas is lower than a threshold value, if yes, the welding is stopped by alarming, and if not, the welding operation is continued.
Preferably, the method further comprises:
and the temperature sensor monitors the welding temperature in real time, judges whether the welding temperature is within a preset welding temperature interval, alarms and stops welding if not, and if yes, continues the welding operation.
Preferably, the method further comprises:
and polishing the arc-collecting point after each welding.
The application has the primary improvement that the welding unit is positioned right above the pipeline butt joint position by moving the welding unit to identify the pipeline butt joint position, and the labor cost is reduced by the automatic control mode. Initializing a welding unit, obtaining an initial position of the welding unit, scanning a butt joint position of a pipeline, obtaining scanning data, obtaining a welding gun position through the scanning data, planning welding parameters and a welding path, and controlling the welding unit to perform welding operation. The welding gun position is obtained through sensor calculation, welding parameters and welding paths are automatically planned, automation of the whole welding process is realized, labor cost is greatly reduced, accuracy errors caused by manual operation are eliminated, and welding accuracy is improved.
Drawings
FIG. 1 is a schematic flow chart of an automatic welding control method;
fig. 2 is a schematic diagram of an external welding station.
Detailed Description
In order to make the technical scheme of the present application better understood by those skilled in the art, the present application will be further described in detail with reference to the following specific embodiments.
The application provides a control method, which is specifically shown in fig. 1, and comprises the following steps:
moving the welding unit, identifying the pipeline butt joint position, judging whether the welding unit is positioned right above the pipeline butt joint position, if not, continuing to move the welding unit until the welding unit is positioned right above the pipeline butt joint position, and if so;
initializing a welding unit, determining the initial position of the welding unit, and scanning the contour of the butt joint position of the pipeline to obtain pre-scanning data;
determining the position of a welding gun according to the pre-scanning data, and planning welding parameters and welding paths;
and controlling the welding unit to perform welding operation according to the welding gun position, the welding parameters and the welding path until the welding operation is completed.
The technical scheme of the application can complete automatic welding through a wired or wireless remote controller and a remote instruction control welding system by one key.
In a preferred embodiment of the application of the method, a welding station integrated with a pipe external welding device is included, which welding station may be a relatively closed box welding station with external welding device, power supply, control system built in, and even a calculator with data edge processing capability. The welding station may allow the passage of welded pipes therethrough and allow for safe and reliable welding of the pipes to be welded within a relatively enclosed space within the welding station. In other embodiments of the present application, the welding station may also be an external welding machine and its auxiliary equipment mounted on a mobile cart, and it should be noted that the method protected by the present application may also be applied to a separate pipe external welding device without a welding station housing, and thus the above-described system or apparatus for applying the method of the present application should not be considered as limiting the application environment of the method of the present application.
In the above preferred embodiment, as shown in fig. 2, the outer welding station includes:
the casing for the suit is peripheral at the pipeline that waits to weld to accessible lifting device or the mobile platform of carrying wholly remove, is provided with in it:
the external welding equipment comprises a groove identification unit, a welding unit, a clamping rail and other auxiliary devices necessary for the external welding equipment.
All the units are connected with a main control unit through cables, the main control unit receives a starting signal, and the welding station is automatically controlled to finish the method disclosed by the application, so that automatic welding of the pipeline is realized. The method specifically comprises the following steps:
after receiving the starting signal;
and driving the welding station to move along the extending direction of the pipeline, detecting the surface of the pipeline below the welding station in real time by the groove identification unit, judging whether a groove exists and the distance between the groove and the groove, and judging whether the welding unit moves to the position above the butt joint position of the grooves of the two pipelines to be welded.
In the preferred embodiment, the groove identification unit is an infrared camera module, the groove identification unit detects an image of the surface of the pipeline in real time, and detects whether the horizontal distance between the current position of the groove identification unit and the butt joint position of the pipeline is smaller than a first precision threshold value, such as 2cm, through an infrared ranging algorithm, if not, the running unit continues to control the welding workstation to move along the extending direction of the pipeline;
when detecting that the current position is smaller than the first precision threshold value, the main control unit controls the traveling unit to stop moving, the welding station moves to the position, and then the external welding equipment accurately adjusts the position of the welding unit relative to the groove to be welded along the sliding rail through the sliding block carried on the welding unit until the horizontal distance between the current position of the groove identification unit and the butt joint position of the pipeline is smaller than the second precision threshold value, such as 1.5mm, so that the welding unit is positioned right above the butt joint position of the pipeline.
In other embodiments of the application, it is also possible to directly drive the slider carried on the welding unit without moving the welding station in its entirety. In addition, the groove identification unit can also be a visible light camera module or a structured light camera module, and the horizontal distance between the current position of the groove identification unit and the butt joint position of the pipeline is detected through a distance calculation algorithm, image identification and other means.
Because the pipeline external welding equipment has larger volume and weight, the traditional external welding equipment often depends on hoisting and manual alignment of constructors, and has larger working strength. According to the application, the groove identification unit is used for identifying the position to be welded when the welding unit moves along the pipeline, and the error possibly generated in the whole movement of the pipeline external welding equipment is eliminated by combining the rough adjustment and the fine adjustment, so that the welding unit can move more accurately above the pipeline butt joint position, and the defect of low automation degree of the pipeline external welding system caused by the fact that the groove butt joint position cannot be aligned effectively in the prior art is overcome.
When the welding unit is positioned right above the butt joint position of the pipeline, initializing the welding unit and determining the initial position of the welding unit, and specifically comprises the following steps:
the clamping unit is controlled to clamp the pipeline to be welded, so that the pipeline to be welded is fixed;
the welding unit is energized to obtain an initial position of the welding unit on the clamping unit.
The clamping unit comprises a clamping rail, a heating coil arranged on the clamping rail and a temperature sensor.
The clamping rail comprises at least two hinged rail parts, the rail parts are connected with clamping air cylinders, the clamping air cylinders are used for driving the rail parts, and the rail parts are surrounded to form an annular rail for clamping and fixing two pipelines to be welded.
In other embodiments of the present application, clamping may be accomplished using hydraulic rams, motor drives, or the like, in addition to clamping cylinders. The clamping rail is determined to be clamped and fixed through travel or stress feedback of a driving device such as a hydraulic push rod or an air cylinder.
Because there may be low temperature weather in some areas, the pipe temperature is too low to be beneficial to the formation of pipe welding seams, so the clamping rail can be further provided with a heating coil for heating the pipe butt joint position, when the clamping is completed, the temperature sensor collects the temperature of the pipe groove area and transmits a temperature data signal to the main control unit, when the pipe butt joint position temperature is lower than a preset temperature, such as 15 ℃, the main control unit controls the heating coil on the clamping rail to heat the pipe butt joint position, in the process, the temperature sensor continuously collects the pipe butt joint position temperature, and when the temperature reaches the preset temperature, the heating coil stops heating. According to the application, the heating coil is integrated on the clamping rail, manual repeated installation is not needed, the requirement on automatic welding under different working conditions is met, and the automatic welding process of equipment is further improved.
The welding unit is provided with a driving motor for driving the welding unit to move along the track, the driving motor is provided with an absolute encoder, when the welding unit is electrified, the initial position of the welding unit on the clamping track is determined through the absolute encoder, and in other embodiments, the welding unit is further provided with an angle sensor for assisting in determining the initial position of the welding unit. The application determines the position of the welding unit through the absolute value encoder, so that the welding unit can execute subsequent actions from the initial position after each welding is finished, and path interference among a plurality of welding units and between the welding unit and other equipment can be avoided.
After initialization is completed, the welding unit scans the pipeline butt joint position profile along the track, specifically, the pipeline butt joint position profile is scanned circumferentially through the laser scanner, a scanning signal is sent to the main control unit, the scanning is recorded as pre-scanning, and pipeline butt joint position profile data including a welding line type, a groove angle, a width, a height, a section area, a misalignment amount and the like are calculated.
And calculating and generating a welding seam central value and required dry extension based on the pipeline butt joint position profile data, and controlling a welding gun to align with the welding seam center by a main control unit according to the welding seam central value and the required dry extension, and adjusting the dry extension of the welding wire to ensure the success rate of arcing without manual verification.
According to the contour data of the butt joint position of the pipeline, extracting a weld joint morphology and inflection points and lowest points in a two-dimensional coordinate system as key point coordinates, planning the number of welding layers and welding beads based on the weld joint morphology, determining the weld joint morphology of each layer, inputting the planned weld joint morphology into a first neural network to predict welding parameters, inputting the predicted welding parameters into a second neural network to reversely predict the weld joint morphology because the output parameters of the first neural network are larger than the input parameters, comparing the planned weld joint morphology with the predicted weld joint morphology, judging whether the error is smaller than a third precision threshold, and outputting the welding parameters predicted by the first neural network if the error is smaller than the third precision threshold; if not, the welding parameters are adjusted, the welding parameters are input into the second neural network again for comparison until the error is smaller than the third precision threshold value, and then the welding parameters are output.
And inputting the planned welding morphology and welding parameters into a third neural network to generate a welding path. In the automatic welding operation process, errors can be accumulated in the procedures of moving a welding station, moving a welding unit, clamping a pipeline and the like, and the errors of moving the welding station, accumulating position offset, track angle offset and the like in the clamping process and the automatic welding operation process are eliminated by utilizing contour scanning of a pipeline butt joint position and welding path planning based on a neural network, so that the welding unit can plan a welding path based on scanning data to form a welding seam meeting the welding quality requirement.
Note that, in this embodiment, all the neural networks are CNN deep learning neural networks.
According to the planned welding parameters and welding paths, controlling a welding unit to weld the butt joint position of the pipeline, wherein in the welding process, a gas sensor monitors the flow, the concentration and the pressure of shielding gas in real time, and when the flow, the concentration and the pressure of the shielding gas are lower than any one of a shielding gas flow threshold value, a shielding gas concentration threshold value and a shielding gas pressure threshold value, the welding is alarmed and stopped, and in the embodiment, the shielding gas adopts the mixed gas of argon and carbon dioxide;
in the welding process, the temperature sensor monitors the welding temperature in real time, and when the welding temperature is not in a welding temperature range, such as 800-1600 ℃, the welding is alarmed and stopped.
More preferably, after each welding is completed, the welding unit is controlled to return to the initial position, the butt joint positions of the pipelines are scanned to obtain the shape of the welded seam of the current welding, if the shape of the welded seam accords with the planned shape of the welded seam, the next welding is performed, and if the shape of the welded seam does not accord with the planned shape of the welded seam, the welding is alarmed and stopped, so that the welding quality of the butt joint positions of the pipelines is ensured.
It should be noted that, after the welding is completed, it is further determined whether the welding is the last welding based on the path planning, so as to feed back that the external welding of the pipeline is completed.
In a more preferred embodiment, after each welding, the main control unit controls the polishing unit to polish the arc receiving point, and sends a polishing completion signal to the main control unit, so that the welding unit starts from an initial position and performs the next welding.
In another embodiment provided by the application, the profile scanning and welding of the pipeline butt joint positions can be performed simultaneously or in a staggered manner. For example, a plurality of welding units, such as two welding units, can be arranged on the clamping rail, the main control unit sends out a control signal to start welding operation, the laser sensor carried by the first welding unit in front works to scan the butt joint position of the pipeline, the scanning signal is sent to the main control unit, the main control unit plans the welding path and the welding parameters in real time, and sends the welding parameters and the welding path to the second welding unit to perform welding operation, and the second welding unit starts welding operation until welding is completed in the process that the first welding unit scans the butt joint position of the pipeline. The initial positions of the first welding unit and the second welding unit are obtained through the multi-circle absolute value encoder, so that the first welding unit and the second welding unit can be prevented from colliding when moving according to a welding path, scanning and welding operations are performed simultaneously, welding efficiency is improved, and engineering time is shortened.
The foregoing is merely a preferred embodiment of the present application, and it should be noted that the above-mentioned preferred embodiment should not be construed as limiting the application, and the scope of the application should be defined by the appended claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the application, and such modifications and adaptations are intended to be comprehended within the scope of the application.

Claims (11)

1. An automatic weld control method, the method comprising:
moving the welding unit, identifying the pipeline butt joint position, judging whether the welding unit is positioned right above the pipeline butt joint position, if not, continuing to move the welding unit until the welding unit is positioned right above the pipeline butt joint position, and if so;
initializing a welding unit, determining the initial position of the welding unit, and scanning the contour of the butt joint position of the pipeline to obtain pre-scanning data;
based on the initial position of the welding unit and the pre-scanning data, adjusting the angle and the dry extension of the welding gun, and determining the position of the welding gun;
extracting key point coordinates of the pipeline butt joint position and morphology of the pipeline butt joint position based on the pre-scanning data;
the number of welding layers and welding beads is planned according to the shape of the butt joint position of the pipeline, and the shape of the welding seam of each welding layer and each welding bead is estimated;
inputting the weld morphology of each welding layer and each welding bead into a first neural network, and predicting welding parameters required to be used;
sending the welding parameters into a second neural network, and reversely predicting the shape of the weld;
comparing the predicted weld morphology with the weld morphology of each welding layer and each welding bead, judging whether a third precision threshold is met, outputting welding parameters if yes, adjusting the welding parameters if no, and re-comparing;
inputting the welding parameters and the key point coordinates into a third neural network to generate a welding path;
and controlling the welding unit to perform welding operation according to the welding gun position, the welding parameters and the welding path until the welding operation is completed.
2. The automatic welding control method according to claim 1, wherein the step of identifying the pipe joint position and judging whether the welding unit is located directly above the pipe joint position comprises:
based on the groove identification unit, detecting the groove position of the pipeline, driving the welding unit to move to the position above the butt joint position of the pipeline, and when the groove identification unit detects that the distance between the welding unit and the butt joint position of the pipeline in the extending direction of the pipeline is smaller than a first precision threshold value, finely adjusting the welding unit to enable the horizontal distance between the welding unit and the butt joint position of the pipeline to be smaller than a second precision threshold value.
3. The automatic welding control method according to claim 2, wherein the groove recognition unit includes a visible light camera module, an infrared camera module, or a structured light camera module.
4. The automatic welding control method according to claim 1, wherein the step of initializing the welding unit and determining an initial position of the welding unit includes:
the clamping unit is controlled to clamp the pipeline, whether the clamping is stable or not is judged, and if yes, the clamping unit is controlled to clamp the pipeline;
the welding unit is energized to obtain an initial position of the welding unit on the clamping unit.
5. The automatic welding control method according to claim 4, wherein the process of obtaining the initial position of the welding unit is:
and calculating the absolute value position of the driving motor according to the multi-circle absolute value decoder of the driving motor of the welding unit, and taking the absolute value position as the initial position of the welding unit.
6. The automatic weld control method of claim 4, further comprising:
and collecting the pipeline temperature of the pipeline butt joint position area, judging whether the temperature is smaller than the preset temperature, if so, heating the area through a heating coil on the clamping unit until the pipeline temperature of the area is not smaller than the preset temperature, and entering the next step.
7. The method of automatic weld control according to claim 1, wherein the step of scanning the pipeline docking position profile to obtain pre-scan data comprises:
and performing circumferential scanning on the pipeline butt joint position based on the initial position of the welding unit to obtain pre-scanning data of the pipeline butt joint position along the circumferential direction, wherein the pre-scanning data comprises one or more of weld joint type, groove angle, width, height, tangential surface area and misalignment amount.
8. The automatic welding control method according to claim 1, wherein the process of extracting the key point coordinates of the pipe butt joint position is:
and according to the pre-scanning data, using the inflection point and the lowest point as key point coordinates in a two-dimensional coordinate system.
9. The automatic weld control method of claim 1, wherein during the welding operation comprises:
the gas sensor monitors the flow rate, the concentration and the pressure of the shielding gas in real time, judges whether any one of the flow rate, the concentration and the pressure of the shielding gas is lower than a threshold value or not respectively, alarms and stops welding if yes, and continues welding operation if not.
10. The automatic weld control method according to claim 1, further comprising:
and the temperature sensor monitors the welding temperature in real time, judges whether the welding temperature is within a preset welding temperature interval, alarms and stops welding if not, and if yes, continues the welding operation.
11. The automatic weld control method of claim 1, wherein the welding operation further comprises:
and polishing the arc-collecting point after each welding.
CN202210067367.XA 2022-01-20 2022-01-20 Automatic welding control method Active CN114273754B (en)

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