CN115302053B - Intelligent submerged arc welding method for stainless steel composite plate - Google Patents
Intelligent submerged arc welding method for stainless steel composite plate Download PDFInfo
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- CN115302053B CN115302053B CN202211054920.2A CN202211054920A CN115302053B CN 115302053 B CN115302053 B CN 115302053B CN 202211054920 A CN202211054920 A CN 202211054920A CN 115302053 B CN115302053 B CN 115302053B
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- 238000003466 welding Methods 0.000 title claims abstract description 195
- 238000000034 method Methods 0.000 title claims abstract description 52
- 239000010935 stainless steel Substances 0.000 title claims abstract description 51
- 229910001220 stainless steel Inorganic materials 0.000 title claims abstract description 51
- 239000002131 composite material Substances 0.000 title claims abstract description 47
- 238000001514 detection method Methods 0.000 claims abstract description 35
- 230000008569 process Effects 0.000 claims abstract description 32
- 239000000463 material Substances 0.000 claims abstract description 28
- 238000009826 distribution Methods 0.000 claims abstract description 18
- 230000007704 transition Effects 0.000 claims abstract description 8
- 238000007689 inspection Methods 0.000 claims abstract description 4
- 230000005540 biological transmission Effects 0.000 claims description 29
- 239000010410 layer Substances 0.000 claims description 24
- 230000007246 mechanism Effects 0.000 claims description 17
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 15
- 230000033001 locomotion Effects 0.000 claims description 11
- 229910052742 iron Inorganic materials 0.000 claims description 8
- 238000003860 storage Methods 0.000 claims description 6
- 238000004458 analytical method Methods 0.000 claims description 5
- 239000011247 coating layer Substances 0.000 claims description 5
- 230000004907 flux Effects 0.000 claims description 5
- 229910000838 Al alloy Inorganic materials 0.000 claims description 4
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 4
- 229910001209 Low-carbon steel Inorganic materials 0.000 claims description 4
- 238000005253 cladding Methods 0.000 claims description 4
- 230000002159 abnormal effect Effects 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 238000007514 turning Methods 0.000 claims description 3
- 210000001503 joint Anatomy 0.000 claims description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000002905 metal composite material Substances 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
- B23K33/004—Filling of continuous seams
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/124—Circuits or methods for feeding welding wire
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
- B23K2103/05—Stainless steel
Abstract
The invention provides an intelligent submerged arc welding method for stainless steel composite plates, which is characterized in that an X-shaped groove is processed at the welding position of two stainless steel composite plates to be welded, two datum points are arranged at the tail end position of the groove, a Cartesian three-dimensional space coordinate system is established by adopting an intelligent control device, the three-dimensional detection of the welding groove is carried out, the aim of accurate detection can be achieved, the arc length to be adjusted is perceived in advance, and the uniform transition of the arc length adjustment process is realized. According to the invention, the technological parameters monitored in real time by the laser radar detection device and the infrared detector are compared with the preset technological parameters, so that the accurate control is realized, the welding accuracy is ensured, meanwhile, a weld temperature distribution cloud chart is generated, the position with larger temperature deviation is identified, and the key position guidance can be provided for quality inspection after welding is completed. During welding, the welding wire replacement and distribution device which is designed by self is used for automatically replacing and distributing welding materials, and the whole welding process is more flexible and efficient.
Description
Technical Field
The invention belongs to the technical field of welding, and particularly relates to an intelligent submerged arc welding method for a stainless steel composite plate.
Background
The stainless steel composite plate is a metal composite material which takes low carbon steel or low alloy steel as a base layer and stainless steel as a coating layer, and the metal composite material not only has the same corrosion resistance and strength as the stainless steel with the same thickness, but also has low manufacturing cost, thus being widely applied. However, the existing intelligent submerged-arc welding technology of the stainless steel composite plate is not mature enough, is influenced by artificial factors and machining precision, and has different sizes of different groove positions, so that arc lengths of different groove positions in the welding process are different, and welding quality is different; the welding process is difficult to detect by the special flux covering influence of the submerged arc welding process, and the accurate control of the welding process cannot be realized; in addition, the composite board welding needs to adopt multiple welding wires, and the existing welding wire replacement adopts a manual mode, so that when the welding workload is large, the welding wires need to be repeatedly replaced manually, the process is tedious, the automation degree and the intelligent degree are low, and the welding efficiency and the quality are seriously influenced.
Disclosure of Invention
Aiming at the defects existing in the prior art, the invention provides the intelligent submerged-arc welding method for the stainless steel composite plate, which can accurately detect the process parameters such as arc length, arc length allowable error, bath maximum temperature, temperature allowable fluctuation range and the like and automatically replace welding wires when the stainless steel composite plate is welded, thereby realizing the accurate control and adjustment of the welding process and effectively ensuring the welding quality.
The present invention achieves the above technical object by the following technical means.
An intelligent submerged arc welding method for a stainless steel composite plate comprises the following steps:
step 1: preparing a stainless steel composite plate and a welding material, and performing groove processing;
step 2: setting a positioning datum point on the stainless steel composite plate at a position close to the tail end of the groove;
step 3: the method comprises the steps of initially positioning the submerged arc welding machine, and establishing a Cartesian three-dimensional space coordinate system based on an intelligent control device;
step 4: inputting preset welding control parameters into an intelligent control device;
step 5: adjusting the initial position of the bottom of the welding gun;
step 6: generating a welding gun movement and height adjustment scheme, and performing welding operation;
step 7: detecting the temperature of a welding pool in real time by utilizing an infrared detector in the intelligent control device, forming a coordinate-temperature distribution cloud picture of a welding line, and identifying abnormal states;
step 8: repeating the steps 4 to 7 until the front base layer part between the two stainless steel composite plates is welded;
step 9: turning over the two stainless steel composite boards, repeating the steps 2 to 7, determining the datum point again, continuing to weld the back base layer part between the two stainless steel composite boards, replacing welding materials after the base layer is completely welded, and sequentially welding the transition layer and the coating.
Further, in the step 1, the welding materials include a base layer welding material, a cladding welding material and a transition layer welding material, the base layer material of the stainless steel composite board is low carbon steel/low alloy steel, and the cladding material is stainless steel; the groove is processed into an X-shaped groove, and the groove angle is 60 degrees.
Further, the specific process of the step 2 is as follows: the method comprises the steps of butt-jointing two stainless steel composite plates to be welded on a welding platform, forming an X-shaped groove, arranging two positioning datum points on the surfaces of the two stainless steel composite plates at the tail end positions close to the X-shaped groove, wherein the two positioning datum points are respectively positioned on two sides of the X-shaped groove, have a distance of 500-1000 mm from the X-shaped groove, are symmetrically distributed based on the extending direction of the X-shaped groove, and are respectively defined as a first datum point and a second datum point.
Further, in the step 3, the specific process of the preliminary positioning submerged arc welding machine is as follows: placing a submerged arc welding machine above an initial section of a to-be-welded part of the stainless steel composite plate, aligning a welding gun to the center of the X-shaped groove, aligning and leveling the submerged arc welding machine, and performing primary positioning of the submerged arc welding machine;
the intelligent control device comprises a controller, an arithmetic unit, a memory, a storage device, a laser radar detection device, an infrared detector and a touch screen for realizing parameter input, wherein the laser radar detection device and the infrared detector are relatively fixed with the bottom of the welding gun and are respectively positioned at the front side and the rear side of the welding gun; the specific process for establishing the Cartesian three-dimensional space coordinate system based on the intelligent control device comprises the following steps: firstly, aligning and locking a first datum point of a laser radar detection device, setting the datum point coordinate as (0, 0) through a touch screen, then aligning the laser radar detection device to the extending direction of an X-type groove starting section, setting the extending direction of the X-type groove as a y-axis, and automatically generating a Cartesian three-dimensional space coordinate system which takes the first datum point as an original point coordinate, takes the extending direction of the X-type groove as the y-axis, takes the horizontal vertical direction of the y-axis as the X-axis and takes the vertical direction of the y-axis as the z-axis through an arithmetic unit;
the laser radar detection device is aligned with the second datum point, the space coordinates of the second datum point are automatically generated through the arithmetic unit, whether the first datum point coordinates are (0, 0) or not is checked based on the second datum point, the position information of each datum point is ensured to be accurate, the initial space coordinates of the position of the submerged arc welding machine are generated, and the datum point information data are stored in the storage device.
Further, in the step 4, the preset welding control parameters include arc length, arc length allowable error, bath maximum temperature, and temperature allowable fluctuation range, wherein the arc length allowable error is 0.1mm, and the temperature allowable fluctuation range is preferably 5%.
Further, the specific process of the step 5 is as follows: the laser radar detection device automatically detects the distance from the end part of the welding wire to the root part of the X-shaped groove, namely the initial arc length, the arithmetic unit compares and analyzes the initial arc length with preset welding control parameters, and the controller sends an instruction to the welding gun movement mechanism according to the analysis result, adjusts the height of the welding gun and then covers the submerged arc welding flux.
Further, the specific process of the step 6 is as follows: the signal transmitting device in the laser radar detection device is aligned to an X-shaped groove area within a 90-degree range in front of the signal transmitting device and transmits laser within a 30-degree range in back of the signal transmitting device, then the signal receiving device receives a reflected signal of the laser from an obstacle, amplifies the reflected signal and stores the amplified signal into a memory, and the arithmetic unit is communicated based on a three-dimensional laser scanning technologyAutomatically generating an X-shaped groove area three-dimensional point cloud model through an algorithm, and automatically analyzing and calculating three-dimensional coordinate position data of the root of the X-shaped groove; then according to the vertical coordinate Z of the root of the X-shaped groove P And the vertical distance delta Z between the bottom of the welding gun and the root of the X-shaped groove, and the Z-direction coordinate Z of the bottom of the welding gun at each welding point in the extending direction of the X-shaped groove is calculated by using the following formula q ：
Z q ＝Z p +ΔZ
Then draw Z q The corresponding relation curve between the X-shaped groove root coordinates and the X-shaped groove root coordinates clearly requires the position adjustment of the welding gun, a welding gun moving and height adjusting scheme is formed, and the controller sends an adjusting instruction to the welding gun moving mechanism according to the corresponding relation curve, and automatically adjusts the height and the position of the welding gun; during the moving process of the welding gun, the position checking is performed in real time based on the first datum point and the second datum point.
Further, in the step 9, the welding material replacement and distribution is performed based on the welding wire replacement and distribution device, the welding wire replacement and distribution device comprises a shell, the shell is fixedly installed on the aluminum alloy bottom support, a motor driving mechanism is installed at the top of the shell, the motor driving mechanism is in signal connection with the intelligent control device, the output end of the motor driving mechanism is connected with a driving shaft, and the driving shaft is positioned in the shell and fixedly connected with the driving bevel gear;
three sets of transmission devices are arranged on the periphery of the shell, the angle between every two adjacent transmission devices is 120 degrees, each transmission device comprises an electromagnetic coil, the top of the box body of each electromagnetic coil is connected with a transmission box, iron blocks are arranged on the outer sides of the box bodies of the electromagnetic coils, and springs are arranged between the iron blocks and the electromagnetic coils; the driven shaft is rotatably arranged in the transmission box, one end of the driven shaft extends into the shell, the end part of the driven shaft is fixedly provided with a driven bevel gear, the other end of the driven shaft is fixedly provided with a driven spur gear, the driven spur gear is meshed with and transmitted with two wire feeding gears, the two wire feeding gears are respectively and fixedly arranged on the two transmission shafts, and the end parts of the other ends of the two transmission shafts extend out of the transmission box and are fixedly provided with a wire feeding pulley.
In step 7, the intelligent control device compares and analyzes the recorded value in the coordinate-temperature distribution cloud chart with preset welding control parameter data, marks the position with larger temperature deviation, and provides important position guidance for quality inspection after welding is completed.
The invention has the following beneficial effects:
according to the invention, the laser radar detection device is adopted to perform three-dimensional detection on the welding groove, so that the welding groove is not influenced by small-size welding flux, the purpose of accurate detection can be achieved, the arc length height to be adjusted can be perceived in advance, the arc length adjustment process is uniformly transited, and the stability of the welding process is ensured; according to the invention, the process parameters monitored in real time are compared with the preset process parameters, so that the accurate control is achieved, and the welding accuracy is ensured; according to the invention, an infrared detector is adopted to monitor the welding process, and the position with larger temperature deviation in the welding process is recorded, so that the quality analysis and quality control of the subsequent welding joint are facilitated; the invention also designs a welding wire replacement and delivery device, realizes automatic delivery and replacement of welding materials, is convenient and flexible, and is beneficial to improving welding efficiency.
Drawings
FIG. 1 is a flow chart of a welding method according to the present invention;
FIG. 2 is a schematic diagram of the reference point arrangement in step 2;
FIG. 3 is a schematic view of an X-groove according to the present invention;
FIG. 4 is a schematic diagram illustrating the installation of a lidar detection device according to the present invention;
FIG. 5 is a vertical cross-sectional view of the welding wire replacement and dispensing apparatus of the present invention;
FIG. 6 is a schematic view of a wire feed gear arrangement in accordance with the present invention;
fig. 7 is a schematic view of the arrangement of the gear box according to the present invention.
In the figure: 1-a first datum; 2-a second datum; 3-X type grooves; 4-a laser radar detection device; 5-infrared detector; 6-welding gun; 7-an aluminum alloy bottom bracket; 8-a motor drive mechanism; 9-driving shaft; 10-driving a bevel gear; 11-a transmission box; 12-iron blocks; 13-a spring; 14-a driven shaft; 15-driven bevel gear; 16-driven spur gears; 17-a wire feeding gear; 18-a transmission shaft; 19-a wire feeding pulley; 20-electromagnetic coil.
Detailed Description
The invention will be further described with reference to the drawings and the specific embodiments, but the scope of the invention is not limited thereto.
In the description of the present invention, it should be understood that the directions and positions indicated by the terms "front", "rear", "left", "right", etc. are based on the drawings of the specification and are not to be construed as limiting the present invention; the use of the terms "first," "second," etc. are all for convenience in distinguishing between similar elements and not as a limitation on the invention; the specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
The intelligent submerged-arc welding method of the stainless steel composite plate is shown in fig. 1, and specifically comprises the following steps:
step 1: preparing a stainless steel composite plate and a welding material, and performing groove processing on the stainless steel composite plate at a position to be welded; the stainless steel composite board comprises a base layer and a coating layer, wherein the base layer is made of low-carbon steel/low-alloy steel, the coating layer is made of stainless steel, and the welding materials comprise a base layer welding material, a coating layer welding material and a transition layer welding material; the beveling adopts an X-shaped bevel form as shown in figures 2 and 3, the bevel angle is 60 degrees, and L in figure 3 represents the thickness of the stainless steel composite plate.
Step 2: as shown in fig. 2, two stainless steel composite plates to be welded are placed on a welding platform in a butt joint mode, grooves form an X shape, two positioning datum points are arranged at the tail end positions, close to the X-shaped grooves 3, of the surfaces of the two stainless steel composite plates, the two positioning datum points are respectively located at two sides of the X-shaped grooves 3, the distance between the two positioning datum points and the X-shaped grooves 3 is 500-1000 mm, and the two positioning datum points are respectively defined as a first datum point 1 and a second datum point 2 based on symmetrical distribution of the extending directions of the X-shaped grooves 3.
Step 3: preliminarily positioning the submerged arc welding machine and establishing a Cartesian three-dimensional space coordinate system;
placing a submerged arc welding machine above an initial section of a to-be-welded part of the stainless steel composite plate, aligning a welding gun to the center position of the X-shaped groove 3, aligning and leveling the submerged arc welding machine, and performing primary positioning of the submerged arc welding machine;
establishing a Cartesian three-dimensional space coordinate system based on an intelligent control device on the submerged arc welding machine: the intelligent control device comprises a controller, an arithmetic unit, a memory, a storage device, a laser radar detection device 4, an infrared detector 5 and a touch screen for realizing parameter input; firstly, aligning and locking a first datum point 1 by a laser radar detection device 4, setting datum point coordinates to be (0, 0 and 0) through a touch screen, then aligning the laser radar detection device 4 to the extending direction of the initial section of an X-shaped groove 3, setting the extending direction of the X-shaped groove 3 to be a y axis, and automatically generating a Cartesian three-dimensional space coordinate system which takes the first datum point as an original point coordinate, takes the extending direction of the X-shaped groove 3 as the y axis, takes the horizontal vertical direction of the y axis as the X axis and takes the vertical direction of the y axis as the z axis through an arithmetic unit;
aligning the laser radar detection device 4 with the second datum point 2, automatically generating the space coordinate of the second datum point 2 through an arithmetic unit, checking whether the first datum point 1 coordinate is (0, 0) or not based on the second datum point 2, ensuring that the position information of each datum point is accurate, generating the initial space coordinate of the position of the submerged arc welding machine, and storing the information data of each datum point in a storage device;
as shown in fig. 4, the laser radar detection device 4 and the infrared detector 5 are fixed relative to the bottom of the welding gun 6, and are respectively located at the front side and the rear side of the welding gun 6, and the arithmetic unit automatically generates the coordinate position data of the bottom of the welding gun 6 based on the coordinate position of the laser radar detection device 4 and the relative position of the laser radar detection device and the bottom of the welding gun 6, and can adjust the height of the bottom 6 of the welding gun by adjusting the position of the laser radar detection device 4 in the vertical direction.
Step 4: presetting welding control parameters;
the touch screen of the intelligent control device is input with preset welding control parameters including arc length, arc length allowable error, bath maximum temperature and temperature allowable fluctuation range, wherein in practical application, the arc length and bath maximum temperature can be determined according to the welding process evaluation result, the arc length allowable error is preferably 0.1mm, and the temperature allowable fluctuation range is preferably 5%.
Step 5: adjusting the initial position of the bottom of the welding gun 6;
before the welding starts, the laser radar detection device 4 automatically detects the distance from the end part of the welding wire to the root part of the X-shaped groove 3, namely the initial arc length, the arithmetic unit compares and analyzes the initial arc length with the arc length data preset in the step 4, the controller sends an instruction to the welding gun motion mechanism according to the analysis result, the height of the welding gun 6 is adjusted, the initial adjustment of the arc length is further realized, at the moment, the vertical distance between the bottom of the welding gun 6 and the root part of the X-shaped groove 3 is delta Z, and after the initial adjustment of the arc length is completed, the submerged arc welding flux is covered.
Step 6: generating a welding gun 6 movement and height adjustment scheme;
the laser radar detection device 4 performs three-dimensional imaging and distance detection, a signal transmitting device in the laser radar detection device 4 is aligned to an X-shaped groove 3 area within a range of 90 degrees in front of the laser radar detection device and transmits laser within a range of 30 degrees behind the X-shaped groove 3 area, then a signal receiving device receives a reflected signal of the laser from an obstacle, the reflected signal is amplified and stored in a memory, an arithmetic unit automatically generates a three-dimensional point cloud model of the X-shaped groove 3 area through an algorithm based on a three-dimensional laser scanning technology, and three-dimensional coordinate position data of the root of the X-shaped groove 3 is automatically analyzed and calculated; then according to the vertical coordinate Z of the root of the X-shaped groove 3 p And the vertical distance delta Z between the bottom of the welding gun 6 and the root of the X-shaped groove 3, and the Z-direction coordinate Z of the bottom of the welding gun 6 at each welding point in the extending direction of the X-shaped groove 3 is calculated by using the following method q ：
Z q ＝Z s +ΔZ
Then draw Z q The corresponding relation curve between the X-shaped groove 3 and the root coordinate of the X-shaped groove 3 clearly requires the position adjustment of the welding gun 6 to form a welding gun 6 moving and height adjusting scheme, and the controller sends an adjusting instruction to the welding gun moving mechanism according to the corresponding relation curve and automatically adjusts the height and the position of the welding gun 6;
during the movement of the welding gun 6, the real-time position check is performed based on the first datum point 1 and the second datum point 2, and the welding gun 6 can be controlled to move and work only when the position coordinates of the welding gun obtained through analysis and calculation of the two datum points are the same, otherwise, the movement and welding operation should be interrupted, and the coordinates are reset.
Step 7: generating a weld temperature distribution cloud picture, and identifying abnormal states;
in the welding process, the infrared detector 5 detects the temperature of a welding pool in real time to form a coordinate-temperature distribution cloud picture of a welding line, and compares and analyzes recorded values in the cloud picture with preset control parameter data to identify a position with larger temperature deviation, thereby providing important position guidance for quality inspection after welding is completed.
Step 8: repeating the steps 4 to 7 until the front base layer part between the two stainless steel composite plates is welded;
step 9: turning over the two stainless steel composite boards, repeating the steps 2 to 7, determining the datum point again, continuing to weld the back base layer part between the two stainless steel composite boards, replacing the welding material after the base layer is completely welded, welding the transition layer, replacing the welding material after the transition layer is welded, and welding the coating.
In this embodiment, the process parameters during the welding process are preferably set as shown in table 1 below:
TABLE 1 welding process parameters
In this embodiment, preferably, the welding wire replacement and distribution device shown in fig. 5 to 7 is used to perform the welding material replacement and distribution operation during the welding process; the welding wire replacement and distribution device comprises a shell, wherein the shell is fixedly arranged on an aluminum alloy bottom support 7, a motor driving mechanism 8 is arranged at the top of the shell, the motor driving mechanism 8 is in signal connection with an intelligent control device, the output end of the motor driving mechanism 8 is connected with a driving shaft 9 through a coupling, and the driving shaft 9 is positioned inside the shell and is fixedly connected with a driving bevel gear 10 inside the shell. Three sets of transmission devices are arranged on the periphery of the shell and are respectively used for distributing three welding wires of different types, and the angle between every two adjacent transmission devices is 120 degrees; the transmission device comprises an electromagnetic coil 20, wherein the top of a box body of the electromagnetic coil 20 is connected with a transmission box 11, the outer side of the box body of the electromagnetic coil 20 is provided with an iron block 12, and springs 13 are arranged between the iron block 12 and the electromagnetic coil 20; the driven shaft 14 is rotatably arranged in the transmission box 11, one end of the driven shaft 14 extends into the shell, the end part of the driven shaft 14 is fixedly provided with the driven bevel gear 15, the other end of the driven shaft 14 is fixedly provided with the driven spur gear 16, the driven spur gear 16 is meshed with and transmitted with the two wire feeding gears 17, the two wire feeding gears 17 are respectively and fixedly arranged on the two transmission shafts 18, and the end parts of the other ends of the two transmission shafts 18 extend out of the transmission box 11 and are fixedly provided with the wire feeding pulley 19 for conveying welding wires.
The working principle of the welding wire replacing and distributing device is as follows: when a certain welding wire is required to be distributed, the electromagnetic coil 20 in the transmission device corresponding to the welding wire is electrified, the attractive force between the electromagnetic coil 20 and the iron block 12 is larger than the thrust of the spring 13, the box body of the electromagnetic coil 20 moves towards the center of the shell together with the transmission box 11, so that the driven bevel gear 15 is driven to approach the driving bevel gear 10 to realize 45-degree meshing, the other two electromagnetic coils 20 are powered off, and the other two driven bevel gears 15 are disconnected with the driving bevel gear 10 under the thrust of the spring 13; then, the intelligent control device controls the motor driving mechanism 8 to work, the motor driving mechanism 8 drives the driving shaft 9 and the driving bevel gear 10 to rotate, the driving bevel gear 10 drives the driven bevel gear 15 and the driven shaft 14 to rotate, the driven spur gear 16 is driven to rotate, the driven spur gear 16 drives the two wire feeding gears 17 and the two transmission shafts 18 to rotate, and then the two wire feeding pulleys 19 are driven to rotate, so that wire feeding is achieved.
In order to avoid the case of the electromagnetic coil 20 moving too fast in the power-on initial stage and the power-off initial stage, and ensure safe and stable operation, it is necessary to control the current to slowly rise or fall to a preset value.
The examples are preferred embodiments of the present invention, but the present invention is not limited to the above-described embodiments, and any obvious modifications, substitutions or variations that can be made by one skilled in the art without departing from the spirit of the present invention are within the scope of the present invention.
Claims (7)
1. The intelligent submerged arc welding method for the stainless steel composite plate is characterized by comprising the following steps of:
step 1: preparing a stainless steel composite plate and a welding material, and performing groove processing;
step 2: setting a positioning datum point on the stainless steel composite plate at a position close to the tail end of the groove;
step 3: the method comprises the steps of initially positioning the submerged arc welding machine, and establishing a Cartesian three-dimensional space coordinate system based on an intelligent control device;
step 4: inputting preset welding control parameters into an intelligent control device;
step 5: adjusting the initial position of the bottom of the welding gun (6);
step 6: generating a welding gun (6) movement and height adjustment scheme, and performing welding operation;
step 7: detecting the temperature of a welding pool in real time by using an infrared detector (5) in the intelligent control device, forming a coordinate-temperature distribution cloud picture of a welding line, and identifying abnormal states;
step 8: repeating the steps 4 to 7 until the front base layer part between the two stainless steel composite plates is welded;
step 9: turning over the two stainless steel composite boards, repeating the steps 2 to 7, determining the datum point again, continuing to weld the back base layer part between the two stainless steel composite boards, replacing welding materials after the base layer is completely welded, and sequentially welding the transition layer and the coating layer;
the specific process of the step 2 is as follows: the method comprises the steps that two stainless steel composite plates to be welded are placed on a welding platform in a butt joint mode, grooves form an X shape, two positioning datum points are arranged on the surfaces of the two stainless steel composite plates and close to the tail end position of an X-shaped groove (3), the two positioning datum points are respectively located on two sides of the X-shaped groove (3), the distance between the two positioning datum points and the X-shaped groove (3) is 500-1000 mm, and the two positioning datum points are symmetrically distributed based on the extending direction of the X-shaped groove (3) and are respectively defined as a first datum point (1) and a second datum point (2);
in the step 3, the specific process of the preliminary positioning submerged arc welding machine is as follows: placing a submerged arc welding machine above an initial section of a to-be-welded part of the stainless steel composite plate, aligning a welding gun to the center of an X-shaped groove (3), aligning and leveling the submerged arc welding machine, and performing primary positioning of the submerged arc welding machine;
the intelligent control device comprises a controller, an arithmetic unit, a memory, a storage device, a laser radar detection device (4), an infrared detector (5) and a touch screen for realizing parameter input, wherein the laser radar detection device (4) and the infrared detector (5) are relatively fixed with the bottom of the welding gun (6) and are respectively positioned at the front side and the rear side of the welding gun (6); the specific process for establishing the Cartesian three-dimensional space coordinate system based on the intelligent control device comprises the following steps: firstly, aligning and locking a laser radar detection device (4) to a first datum point (1), setting datum point coordinates to be (0, 0) through a touch screen, then aligning the laser radar detection device (4) to the extending direction of an initial section of an X-shaped groove (3), setting the extending direction of the X-shaped groove (3) to be a y axis, and automatically generating a Cartesian three-dimensional space coordinate system which takes the first datum point as an original point coordinate, takes the extending direction of the X-shaped groove (3) as a y axis, takes the horizontal vertical direction of the y axis as an X axis and takes the vertical direction of the y axis as a z axis through an arithmetic unit;
the specific process of the step 6 is as follows: the signal transmitting device in the laser radar detection device (4) is aligned with the X-shaped groove (3) area within the range of 90 degrees in front of the signal transmitting device and transmits laser within the range of 30 degrees in back of the signal transmitting device, then the signal receiving device receives the reflected signal of the laser from the obstacle, amplifies the reflected signal and stores the amplified signal into a memory, and based on the three-dimensional laser scanning technology, the arithmetic unit automatically generates a three-dimensional point cloud model of the X-shaped groove (3) area through an algorithm, and three-dimensional coordinate position data of the root of the X-shaped groove (3) is automatically analyzed and calculated; then according to the vertical coordinate Z of the root of the X-shaped groove (3) p And the vertical distance delta Z between the bottom of the welding gun (6) and the root of the X-shaped groove (3), and the Z-direction coordinate Z of the bottom of the welding gun (6) at each welding point in the extending direction of the X-shaped groove (3) is calculated by using the following formula q ：
Z q ＝Z p +ΔZ
Then draw Z q The corresponding relation curve between the X-shaped groove (3) and the vertical coordinate of the root of the X-shaped groove (3) clearly requires the position adjustment of the welding gun (6), so as to form a scheme for adjusting the movement and the height of the welding gun (6), and the controller sends an adjusting instruction to a welding gun movement mechanism according to the scheme, so that the height and the position of the welding gun (6) are automatically adjusted; based on the first part during the movement of the welding gun (6)The datum point (1) and the second datum point (2) are subjected to real-time position checking.
2. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 1, the welding materials comprise a base layer welding material, a cladding welding material and a transition layer welding material, the base layer material of the stainless steel composite plate is low carbon steel or low alloy steel, and the cladding material is stainless steel; the groove is processed into an X-shaped groove, and the groove angle is 60 degrees.
3. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 3, reference points are checked after the cartesian three-dimensional space coordinate system is established, the laser radar detection device (4) is aligned to the second reference point (2), the space coordinates of the second reference point (2) are automatically generated through the arithmetic unit, then whether the coordinates of the first reference point (1) are (0, 0) is checked based on the second reference point (2), the position information of each reference point is ensured to be accurate, the initial space coordinates of the position of the submerged arc welding machine are generated, and the information data of each reference point is stored in the storage device.
4. The intelligent submerged arc welding method for the stainless steel composite plate according to claim 1, wherein in the step 4, the preset welding control parameters comprise arc length, arc length allowable error, bath maximum temperature and temperature allowable fluctuation range, the arc length allowable error is 0.1mm, and the temperature allowable fluctuation range is preferably 5%.
5. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein the specific process of the step 5 is as follows: the laser radar detection device (4) automatically detects the distance from the end part of the welding wire to the root part of the X-shaped groove (3), namely the initial arc length, the arithmetic unit compares and analyzes the initial arc length with preset welding control parameters, and the controller sends an instruction to the welding gun movement mechanism according to the analysis result, adjusts the height of the welding gun (6) and then covers the submerged arc welding flux.
6. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 9, welding material replacement and distribution are performed based on a welding wire replacement and distribution device, the welding wire replacement and distribution device comprises a shell, the shell is fixedly arranged on an aluminum alloy base (7), a motor driving mechanism (8) at the top of the shell is in signal connection with an intelligent control device, the output end of the motor driving mechanism (8) is connected with a driving shaft (9), and the driving shaft (9) is positioned in the shell and is fixedly connected with a driving bevel gear (10);
three sets of transmission devices are arranged on the periphery of the shell, the angle between every two adjacent transmission devices is 120 degrees, each transmission device comprises an electromagnetic coil (20), the top of the box body of each electromagnetic coil (20) is connected with a transmission box (11), iron blocks (12) are arranged on the outer side of the box body of each electromagnetic coil (20), and springs (13) are arranged between each iron block (12) and each electromagnetic coil (20); the driven shaft (14) is rotatably arranged in the transmission box (11), one end of the driven shaft (14) extends into the shell and is fixedly provided with the driven bevel gear (15), the other end of the driven shaft is fixedly provided with the driven spur gear (16), the driven spur gear (16) is meshed with the two wire feeding gears (17), the two wire feeding gears (17) are fixedly arranged on the two transmission shafts (18) respectively, and the other end parts of the two transmission shafts (18) extend out of the transmission box (11) and are fixedly provided with the wire feeding pulley (19).
7. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 7, the intelligent control device compares and analyzes the recorded value in the coordinate-temperature distribution cloud chart with preset welding control parameter data, marks the position with larger temperature deviation, and provides important position guidance for quality inspection after welding is completed.
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| CN202211054920.2A CN115302053B (en) | 2022-08-29 | 2022-08-29 | Intelligent submerged arc welding method for stainless steel composite plate |
| PCT/CN2023/085082 WO2024045598A1 (en) | 2022-08-29 | 2023-03-30 | Intelligent submerged arc welding method for stainless-steel composite plate |
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| WO2024045598A1 (en) | 2024-03-07 |
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