CN115582604A - Gantry type multi-station welding system and method for large-diameter pipeline - Google Patents
Gantry type multi-station welding system and method for large-diameter pipeline Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23K9/00—Arc welding or cutting
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- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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- 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
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Abstract
本发明涉及一种大口径管道龙门式多工位焊接系统及焊接方法,包括龙门架,龙门架上设置升降台,升降台上轴向固定设置直线导轨,升降台上沿管道轴线方向固定设置若干组固定焊接装置,直线导轨上滑动设置若干组活动焊接装置,若干组活动焊接装置滑动调整好位置后分别通过锁定机构固定在直线导轨上。通过上述设置,在升降台和直线导轨上均设置若干组焊接装置,可以同时对多条环缝进行焊接,提高生产效率;直线导轨固定在升降台上,可以对升降台同步升降,从而实现对固定焊接装置和活动焊接装置同步升降的控制,操作方便。若干组活动焊接装置可以在直线导轨上滑动以调整位置,从而能够适应不同长度的管道的环缝焊接,操作方便,节省了成本。
The invention relates to a gantry-type multi-station welding system and welding method for large-diameter pipelines, including a gantry frame, a lifting table is arranged on the gantry frame, linear guide rails are fixedly arranged on the lifting table in the axial direction, and several One set of fixed welding devices, several groups of movable welding devices are slidingly set on the linear guide rail, and several groups of movable welding devices are slid and adjusted to the position and fixed on the linear guide rail through locking mechanisms respectively. Through the above settings, several sets of welding devices are installed on the lifting platform and the linear guide rail, which can weld multiple circular seams at the same time to improve production efficiency; the linear guide rail is fixed on the lifting platform and can lift the lifting platform synchronously, so as to realize The fixed welding device and the movable welding device are synchronously lifted and lowered, and the operation is convenient. Several groups of movable welding devices can slide on the linear guide rail to adjust the position, so as to be able to adapt to the circular seam welding of pipes of different lengths, which is easy to operate and saves cost.
Description
技术领域technical field
本发明属于龙门式焊机技术领域,具体涉及一种大口径管道龙门式多工位焊接系统及焊接方法。The invention belongs to the technical field of gantry-type welding machines, and in particular relates to a gantry-type multi-station welding system and a welding method for large-diameter pipelines.
背景技术Background technique
因大口径不锈钢及特种合金环焊管其良好的耐腐蚀性,适用于化工,船舶等特殊行业。现有技术中对于大口径不锈钢及特种合金管道的焊接采用龙门焊机来实现,龙门焊机通常只设置一组焊接装置,一次只能焊接一条外环缝,焊接效率低。Due to the good corrosion resistance of large-diameter stainless steel and special alloy girth welded pipes, it is suitable for special industries such as chemical industry and shipbuilding. In the prior art, the welding of large-diameter stainless steel and special alloy pipes is realized by a gantry welding machine. Usually, the gantry welding machine is only equipped with one set of welding devices, and can only weld one outer ring seam at a time, and the welding efficiency is low.
发明内容Contents of the invention
本发明的目的在于克服现有技术中的龙门焊机对管道的焊接效率低的技术缺陷,从而提供了一种大口径管道龙门式多工位焊接系统。The purpose of the present invention is to overcome the technical defect of low welding efficiency of the gantry welding machine in the prior art for pipelines, thereby providing a gantry-type multi-station welding system for large-diameter pipelines.
为了解决上述问题,本发明提供了一种大口径管道龙门式多工位焊接系统,包括龙门架,龙门架上设置升降台,升降台上沿管道轴向固定设置直线导轨,升降台上沿管道轴线方向固定设置若干组固定焊接装置,直线导轨上滑动设置若干组活动焊接装置,若干组活动焊接装置滑动至合适位置后分别通过锁定机构固定在直线导轨上。In order to solve the above problems, the present invention provides a gantry-type multi-station welding system for large-diameter pipelines, which includes a gantry frame, a lifting table is arranged on the gantry frame, and a linear guide rail is fixedly arranged on the lifting table along the axial direction of the pipeline. Several groups of fixed welding devices are fixedly installed in the axial direction, and several groups of movable welding devices are slidably arranged on the linear guide rail. After sliding to a suitable position, several groups of movable welding devices are respectively fixed on the linear guide rail by locking mechanisms.
可选地,固定焊接装置设置为两组,分别为第一焊枪装置和第二焊枪装置;第一焊接装置包括第一焊枪组件,第一焊枪组件固定在升降台上,第二焊枪装置包括电动滑架和第二焊枪组件,电动滑架固定在升降台上,第二焊枪组件滑动设置在电动滑架上。可选地,活动焊接装置包括电动十字大滑架、电动十字小滑架和活动焊枪组件,活动焊枪组件滑动安装在电动十字小滑架上,电动十字小滑架滑动安装在电动十字大滑架上Optionally, the fixed welding devices are arranged in two groups, namely the first welding torch device and the second welding torch device; The sliding frame and the second welding torch assembly, the electric sliding frame is fixed on the lifting platform, and the second welding torch assembly is slidably arranged on the electric sliding frame. Optionally, the movable welding device includes a large electric cross carriage, a small electric cross carriage and a movable welding torch assembly, the movable welding gun assembly is slidably installed on the small electric cross carriage, and the small electric cross carriage is slidably installed on the large electric cross carriage superior
可选地,还包括控制系统,第一焊枪组件、第二焊枪组件、电动滑架、电动十字大滑架、电动十字小滑架和活动焊枪组件分别与控制系统电气连接。控制系统控制电动十字小滑架在电动十字大滑架上沿横向和竖向滑动,控制系统控制活动焊枪组件在电动十字小滑架上沿横向和竖向滑动。Optionally, a control system is also included, and the first welding torch assembly, the second welding torch assembly, the electric carriage, the electric large cross carriage, the electric cross small carriage and the movable welding torch assembly are respectively electrically connected to the control system. The control system controls the small electric cross slide to slide horizontally and vertically on the large electric cross slide, and the control system controls the movable welding torch assembly to slide horizontally and vertically on the small electric cross slide.
可选地,还包括固定在地面的固定架,直线导轨的一端固定连接在升降台上,直线导轨的另一端通过弹簧平衡器悬挂在固定架上。Optionally, a fixed frame fixed on the ground is also included, one end of the linear guide rail is fixedly connected to the lifting platform, and the other end of the linear guide rail is suspended on the fixed frame through a spring balancer.
可选地,固定架包括若干竖管和若干横管焊接围成的框架,弹簧平衡器的上端连接于框架上部,弹簧平衡器的下端连接于直线滑轨的一端。Optionally, the fixed frame includes a frame formed by welding several vertical pipes and several horizontal pipes, the upper end of the spring balancer is connected to the upper part of the frame, and the lower end of the spring balancer is connected to one end of the linear slide rail.
可选地,所述固定焊接装置和所述活动焊接装置中的焊接组件均采用TIG焊接组件。Optionally, the welding components in the fixed welding device and the movable welding device both use TIG welding components.
可选地,管道的长度为1.5米、2米或3米。Optionally, the length of the pipe is 1.5 meters, 2 meters or 3 meters.
本发明的另一目的在于公开了一种焊接方法,包括所述的大口径管道龙门式多工位焊接系统,包括以下步骤:Another object of the present invention is to disclose a welding method, including the large-diameter pipeline gantry-type multi-station welding system, including the following steps:
S1:通过控制系统调节升降台的高度以适应管道的口径,通过控制系统调节第一焊枪组件、电动滑架、电动十字小滑架、电动十字大滑架和活动焊枪组件的位置以适应管道的长度,使得每两个相邻管道之间均对应设置一组焊接装置;S1: Adjust the height of the lifting platform through the control system to adapt to the diameter of the pipeline, adjust the positions of the first welding torch assembly, electric carriage, electric cross carriage, electric cross large carriage and movable welding torch assembly through the control system to adapt to the pipe diameter Length, so that a set of welding devices is correspondingly installed between every two adjacent pipes;
S2:通过控制系统控制其中一组或一组以上的焊接装置同时对管道的环缝进行焊接。S2: Control one group or more than one group of welding devices through the control system to weld the circumferential seam of the pipeline at the same time.
与现有技术相比,本发明的有益效果:Compared with prior art, the beneficial effect of the present invention:
1、本发明的大口径管道龙门式多工位焊接系统中,在升降台和直线导轨上均设置若干组焊接装置,可以同时对多条环缝进行焊接,提高生产效率;直线导轨固定在升降台上,可以对升降台同步升降,从而实现对固定焊接装置和活动焊接装置同步升降的控制,操作方便。若干组活动焊接装置可以在直线导轨上滑动以调整位置,从而能够适应不同长度的管道的环缝焊接,操作方便,节省了成本。1. In the gantry-type multi-station welding system for large-diameter pipelines of the present invention, several sets of welding devices are installed on the lifting platform and the linear guide rail, which can weld multiple circular seams at the same time to improve production efficiency; the linear guide rail is fixed on the lifting platform. On the platform, the lifting platform can be lifted and lowered synchronously, so as to realize the control of the synchronous lifting of the fixed welding device and the movable welding device, and the operation is convenient. Several groups of movable welding devices can slide on the linear guide rail to adjust the position, so as to adapt to the circular seam welding of pipes of different lengths, which is convenient to operate and saves cost.
2、本发明的大口径管道龙门式多工位焊接系统中,本发明是在原有环缝龙门焊机的焊接系统基础上增加了三个TIG焊接装置,对原设备改动小,提高了生产效率,增加了利润。2. In the large-diameter pipeline gantry-type multi-station welding system of the present invention, the present invention adds three TIG welding devices on the basis of the welding system of the original circular seam gantry welding machine, which makes little modification to the original equipment and improves the production efficiency , increased profits.
3、本发明的大口径管道龙门式多工位焊接系统中,弹簧平衡器的设置,保证了直线导轨随升降台上升和下降过程中保持水平位置,移动稳定性好。3. In the large-diameter pipeline gantry-type multi-station welding system of the present invention, the setting of the spring balancer ensures that the linear guide rail maintains a horizontal position during the process of rising and falling with the lifting platform, and the movement stability is good.
4、本发明的大口径管道龙门式多工位焊接系统中,通过设置直线导轨、电动十字大滑架和电动十字小滑架的配合,可以实现不同长度管道的环缝焊接,适应性好,从而节省了设备成本。4. In the gantry-type multi-station welding system for large-diameter pipelines of the present invention, through the cooperation of linear guide rails, large electric cross carriages and small electric cross carriages, circular seam welding of pipes with different lengths can be realized, and the adaptability is good. Thereby saving equipment cost.
附图说明Description of drawings
图1为本实施例中焊接系统的结构示意图;Fig. 1 is the structural representation of welding system in the present embodiment;
图2为本实施例中焊接1.5米管道的焊枪组件位置关系图;Fig. 2 is a positional diagram of the welding torch assembly for welding 1.5 meters of pipelines in the present embodiment;
图3为本实施例中焊接2米管道的焊枪组件位置关系图;Fig. 3 is the positional relationship diagram of the welding torch assembly of welding 2 meters pipeline in the present embodiment;
图4为本实施例中焊接3米管道的焊枪组件位置关系图。Fig. 4 is a position relation diagram of the welding torch assembly for welding a 3-meter pipeline in this embodiment.
附图标记:1、龙门架;11、升降台;12、直线导轨;2、第一焊枪装置;21、第一焊枪组件;3、第二焊枪装置;31、第二焊枪组件;32、电动滑架;4、第三焊枪装置;41、第三焊枪组件;5、第四焊枪装置;51、第四焊枪组件;6、电动十字大滑架;61、电动十字小滑架;7、固定架;71、弹簧平衡器;8、管道。Reference signs: 1, gantry frame; 11, lifting platform; 12, linear guide rail; 2, first welding torch device; 21, first welding torch assembly; 3, second welding torch device; 31, second welding torch assembly; 32, electric Slide frame; 4. The third welding torch device; 41. The third welding torch assembly; 5. The fourth welding torch device; 51. The fourth welding torch assembly; 6. The large electric cross carriage; frame; 71, spring balancer; 8, pipeline.
具体实施方式detailed description
下面结合附图和实施例对本发明作进一步的详细描述。The present invention will be described in further detail below in conjunction with the accompanying drawings and embodiments.
实施例Example
如图1-图4所示,本实施例提供了一种大口径管道龙门式多工位焊接系统,包括龙门架1,龙门架1上设置升降台11,升降台11上沿管道8轴向固定设置直线导轨12,升降台11上沿管道8轴线方向固定设置若干组固定焊接装置,直线导轨12上滑动设置若干组活动焊接装置,若干组活动焊接装置滑动至合适位置后分别通过锁定机构固定在直线导轨12上。As shown in Figures 1 to 4, this embodiment provides a large-diameter pipeline gantry-type multi-station welding system, including a
通过上述设置,在升降台11和直线导轨12上均设置若干组焊接装置,可以同时对多条环缝进行焊接,提高生产效率;直线导轨12固定在升降台11上,可以对升降台11同步升降,从而实现对固定焊接装置和活动焊接装置同步升降的控制,操作方便。若干组活动焊接装置可以在直线导轨12上滑动以调整位置,从而能够适应不同长度的管道8的环缝焊接,操作方便,节省了成本。锁定机构可采用现有的常规锁紧件锁紧,比如螺栓等紧固件。Through the above settings, several sets of welding devices are installed on the lifting table 11 and the
本实施例的管道8可以为不锈钢及特种合金管道。The
本实施例的大口径管道龙门式多工位焊接系统中,固定焊接装置设置为两组,分别为第一焊枪装置2和第二焊枪装置3;第一焊枪装置2包括第一焊枪组件21,第一焊枪组件21固定在升降台11上,第二焊枪装置3包括电动滑架32和第二焊枪组件31,电动滑架32固定在升降台11上,第二焊枪组件31滑动设置在电动滑架32上。In the large-caliber pipeline gantry-type multi-station welding system of this embodiment, the fixed welding devices are arranged in two groups, namely the first welding torch device 2 and the second welding torch device 3; the first welding torch device 2 includes a first
通过上述设置,第二焊枪组件31滑动设置在电动滑架32上,方便对第一焊枪组件21的沿管道8的轴线方向的位置进行调节,以适应不同长度的管道8环缝焊接,通过控制系统自动调节第二焊枪组件31的位置,操作方便,节省劳动力,效率高。Through the above setting, the second
本实施例的大口径管道龙门式多工位焊接系统中,具体的,第一焊枪装置2位于第二焊枪装置3的一侧,若干组活动焊接装置位于第二焊枪装置3的另一侧,即第一焊枪装置2位于若干组焊接装置的一端,始终是对管道8的第一条环缝进行焊接,不需要进行横向调节就可以适应不同长度管道8的焊接,节省了成本。In the large-diameter pipeline gantry-type multi-station welding system of this embodiment, specifically, the first welding torch device 2 is located on one side of the second welding torch device 3, and several groups of movable welding devices are located on the other side of the second welding torch device 3, That is, the first welding torch device 2 is located at one end of several groups of welding devices, and always welds the first circular seam of the
本实施例的大口径管道龙门式多工位焊接系统中,活动焊接装置包括电动十字大滑架6、电动十字小滑架61和活动焊枪组件,活动焊枪组件滑动安装在电动十字小滑架61上,电动十字小滑架61滑动安装在电动十字大滑架6上。In the gantry-type multi-station welding system for large-diameter pipelines in this embodiment, the movable welding device includes the electric cross
通过上述设置,活动焊枪组件通过两组电动十字滑架来调节位置,范围更广,精度更高,从而焊接效果更好,以适应不同长度的管道8环缝的焊接。具体的,本实施例中在每把活动焊枪组件上安装两套电动十字滑架。可增大活动焊枪组件的横向和纵向的调整范围,活动焊枪组件移动位置控制更加精准,方便工人操作,保证焊接效果。具体的,采用左右1000mm,上下500mm行程滑架实现同时满足1.5m和2m环缝焊接。Through the above settings, the position of the movable welding torch assembly is adjusted by two sets of electric cross slides, with a wider range and higher precision, so that the welding effect is better, so as to adapt to the welding of 8 ring seams of pipelines of different lengths. Specifically, in this embodiment, two sets of electric cross carriages are installed on each movable welding torch assembly. The horizontal and vertical adjustment ranges of the movable welding torch assembly can be increased, and the moving position control of the movable welding torch assembly is more precise, which is convenient for workers to operate and ensures the welding effect. Specifically, the left and right 1000mm, up and down 500mm travel carriages are used to meet the 1.5m and 2m circular seam welding at the same time.
本实施例的大口径管道龙门式多工位焊接系统中,还包括控制系统,第一焊枪组件21、第二焊枪组件31、电动滑架32、电动十字大滑架6、电动十字小滑架61和活动焊枪组件分别与控制系统电气连接。控制系统控制第一焊枪组件21、第二焊枪组件31和活动焊枪组件的工作,控制系统控制第二焊枪组件31在电动滑架32上滑动,控制系统控制电动十字小滑架61在电动十字大滑架6上沿横向和竖向滑动,控制系统控制活动焊枪组件在电动十字小滑架61上沿横向和竖向滑动。本实施例的大口径管道龙门式多工位焊接系统中,还包括固定在地面的固定架7,直线导轨12的一端固定连接在升降台11上,直线导轨12的另一端通过弹簧平衡器71悬挂在固定架7上。The large-diameter pipeline gantry-type multi-station welding system of this embodiment also includes a control system, the first
通过上述设置,固定架7的设置,用于悬挂直线导轨12,减轻了对升降台11施加的重力,直线导轨12受力更加平衡稳定,升降台11升降运动也更加稳定,从而提高了焊接装置的焊接稳定性。Through the above setting, the setting of the fixed
本实施例的大口径管道龙门式多工位焊接系统中,固定架7包括若干竖管和若干横管焊接围成的框架,弹簧平衡器71的上端连接于框架上部,弹簧平衡器71的下端连接于直线滑轨的一端。In the large-diameter pipeline gantry-type multi-station welding system of this embodiment, the fixed
通过上述设置,弹簧平衡器71的设置,使直线导轨12的另一端悬挂在固定架7上,使直线导轨12受力平衡,并且随升降台11同步升降运动,结构简单,实现了若干组焊接装置的同步升降,以适应不同管径的管道8焊接,操作方便,提高了直线导轨12的稳定性。Through the above setting and the setting of the
具体的,在升降台11的另一侧增加150*100的方管支撑架,在原龙门的平台中心端处安装120*120的方管,用于支撑另外3把焊枪的滑动机械装置。在平台端测装有直线导轨12,方便焊枪中线的调整。直线导轨12的另一侧配套合适的弹簧平衡器71,在不增加原来设备重量基础上保证直线导轨12能够随升降台11稳定上下。Specifically, a 150*100 square tube support frame is added to the other side of the
本实施例的大口径管道龙门式多工位焊接系统中,所述固定焊接装置和所述活动焊接装置中的焊接组件均采用TIG焊接组件。In the gantry-type multi-station welding system for large-diameter pipelines in this embodiment, the welding components in the fixed welding device and the movable welding device both use TIG welding components.
本实施例的大口径管道龙门式多工位焊接系统中,活动焊接装置设置为两组,分别为第三焊枪装置4和第四焊枪装置5。第三焊枪装置4的活动焊枪组件为第三焊枪组件41,第四焊枪装置5的活动焊枪组件为第四焊枪组件51。In the gantry-type multi-station welding system for large-diameter pipelines in this embodiment, the movable welding devices are arranged in two groups, namely the third
本实施例的大口径管道龙门式多工位焊接系统中,管道8的长度为1.5米、2米或3米。In the gantry-type multi-station welding system for large-diameter pipelines in this embodiment, the length of the
具体的,如图2所示,当管道8的长度为1.5米时,第一焊枪组件21、第二焊枪组件31、第三焊枪组件41和第四焊枪组件51之间的间隔距离均为1.5米,可以同时焊接四条环焊缝。Specifically, as shown in Figure 2, when the length of the
如图3所示,当管道8的长度为2米时,调整第二焊枪组件31与第一焊枪组件21之间的间隔距离为2米,调整第三焊枪组件41与第二焊枪组件31的间隔距离为2米,调整第四焊枪装置5在直线导轨12上滑动,并调整第四焊枪组件51在电动十字滑架上的位置,直至第四焊枪组件51与第三焊枪组件41之间的间隔为2米,从而可以同时焊接四条焊缝。As shown in Figure 3, when the length of
如图4所示,当管道8的长度为3米时,调整第三焊枪组件41与第一焊枪组件21的间隔为3米,调整第四焊枪装置5在直线导轨12上滑动,并调整第四焊枪组件51在电动十字滑架上的位置,直至第四焊枪组件51与第三焊枪组件41之间的间隔为3米,启动第一焊枪组件21、第三焊枪组件41和第四焊枪组件51,可以同时焊接三条焊缝。As shown in Figure 4, when the length of the
对本实施例中的大口径不锈钢及特种合金管道8的焊接方法如下:The welding method to the large diameter stainless steel and
S1:通过控制系统调节升降台11的高度以适应管道8的口径,通过控制系统调节第一焊枪组件21、电动十字小滑架61、第二焊枪组件31的位置以适应管道8的长度,使得每两个相邻管道8之间均对应设置一组焊接装置;S1: Adjust the height of the lifting table 11 through the control system to adapt to the diameter of the
S2:通过控制系统控制其中一组或一组以上的焊接装置同时工作对管道8的环缝进行焊接。S2: Control one group or more than one group of welding devices to work at the same time through the control system to weld the circumferential seam of the
具体的,本实施例是在原有环缝龙门焊机的焊接系统基础上增加了三个TIG焊接系统,具体还包括高频引弧器、监视系统、送丝系统和温控制冷水箱等均与控制系统连接。本实施例对原有的焊接系统改造后,设备氩弧焊具备了一键启动、停止功能,操作人员能够根据工件情况快速选择焊接工艺,可以根据实际需要,选择单枪焊接、双枪焊接或四枪同时焊接等,四把焊枪组件可以实现参数的独立设置和独立动作等。经过本实施例的改造之后,加工能力得到了提升,以产品8条焊缝为例,单班可焊接4条焊缝,两班完成成品1支。Specifically, this embodiment adds three TIG welding systems on the basis of the welding system of the original circular seam gantry welding machine, specifically including high-frequency arc starter, monitoring system, wire feeding system and temperature control cold water tank, etc. Control system connection. After the transformation of the original welding system in this embodiment, the argon arc welding equipment has a one-button start and stop function, and the operator can quickly select the welding process according to the workpiece condition, and can choose single-gun welding, double-gun welding or welding according to actual needs. Four torches are welded at the same time, etc., and the four welding torch components can realize independent setting of parameters and independent actions. After the transformation of this embodiment, the processing capacity has been improved, with
进一步的,温控制冷水箱由高效冷凝器、压缩机、风扇电机、温控器和水检测传感器等部件组成,是自动化焊接比如等离子过程和高负载持续状态下焊接时冷却焊枪必备的配套设备。焊枪组件为WP27500A氩弧自动焊枪,主要用于焊接不锈钢、碳钢、钛、锆及其合金等材料。该焊枪具有冷却效果佳、电弧压缩效果好、电弧稳定等特点,是获得良好等离子焊接质量的重要配套件之一。Further, the temperature-controlled cold water tank is composed of high-efficiency condenser, compressor, fan motor, temperature controller and water detection sensor, etc. It is a necessary supporting equipment for cooling welding torch in automatic welding such as plasma process and high-load continuous welding . The welding torch assembly is WP27500A argon arc automatic welding torch, which is mainly used for welding materials such as stainless steel, carbon steel, titanium, zirconium and their alloys. The torch has the characteristics of good cooling effect, good arc compression effect, stable arc, etc. It is one of the important accessories for obtaining good plasma welding quality.
送丝系统包括自动送丝机和送丝支架,该送丝机由直流电机驱动,经微型减速器减速,输出轴上的齿轮与两边带送丝轮的齿轮啮合,送丝轮上方有压紧轮,通过弹簧杠杆压紧,转动偏心轮可改变压紧轮和送丝轮之间压紧力大小。适合于PAW、TIG焊接工艺的低速送丝要求,根据焊丝直径装相应的送丝轮,可输送焊丝直径为Φ0.8、Φ1.0、Φ1.2、Φ1.6。The wire feeding system includes an automatic wire feeding machine and a wire feeding bracket. The wire feeding machine is driven by a DC motor and decelerated by a micro reducer. The gear on the output shaft meshes with the gears with wire feeding wheels on both sides. The wheel is pressed by the spring lever, and the pressing force between the pressing wheel and the wire feeding wheel can be changed by turning the eccentric wheel. It is suitable for the low-speed wire feeding requirements of PAW and TIG welding processes, and the corresponding wire feeding rollers are installed according to the diameter of the welding wire.
送丝支架采用精密三维送丝支架,该装置是实现焊接时送丝最佳角度送入溶池的功能配套件,对于TIG和PAW焊接工艺,具有角度调整方便,占用空间小,焊枪连接简单等功能。The wire feeding bracket adopts a precision three-dimensional wire feeding bracket. This device is a functional accessory that realizes the optimal angle of wire feeding into the molten pool during welding. For TIG and PAW welding processes, it has the advantages of convenient angle adjustment, small space occupation, and simple welding torch connection. Features.
电动十字滑架与电源和控制系统配套可实现电弧高度点动控制和焊枪组件的摆动控制。电动十字滑架由两件互成十字相连的滑板组成,电动十字滑架的调整移动由步进电机带动丝杠旋转,再由螺母带动滑板移动,在外层十字滑架的移动块上固定支承板、焊枪座、焊枪和多维送丝支架等零部件。电弧高度调整滑架和摆动滑架可单独分开安装和应用,在焊接过程中可通过控制按钮点动调节焊枪水平和垂直位置。The electric cross carriage is matched with the power supply and control system to realize the jogging control of the arc height and the swing control of the welding torch assembly. The electric cross slide is composed of two cross-connected slide plates. The adjustment and movement of the electric cross slide is driven by the stepper motor to rotate the screw, and then the nut drives the slide to move, and the support plate is fixed on the moving block of the outer cross slide. , welding torch holder, welding torch and multi-dimensional wire feeding bracket and other components. The arc height adjustment carriage and the swing carriage can be installed and applied separately, and the horizontal and vertical positions of the welding torch can be adjusted by jogging the control buttons during the welding process.
采用焊接可编程控制系统,该控制系统是完成纵缝/环缝焊接过程的中枢系统。采用稳定可靠的西门子PLC控制技术平台。所有控制元件安装于专业控制箱内,远程控制编程面板采用集中式控制布局,全中文人机对话界面,通过编程对系统各组成部分实现联动控制,并可利用远程控制面板及手控盒实现系统常用功能操作。Welding programmable control system is adopted, which is the central system to complete the longitudinal seam/circumferential seam welding process. Adopt stable and reliable Siemens PLC control technology platform. All control components are installed in a professional control box. The remote control programming panel adopts a centralized control layout and a full Chinese man-machine dialogue interface. Through programming, the linkage control of each component of the system is realized, and the remote control panel and hand control box can be used to realize the system. Commonly used function operations.
高频引弧器就近安装提高设备引弧成功率,防止夹钨,钨极烧损等,降低人工操作强度,实现提高焊接效率目的。同时减少因起弧异常带来的焊接缺陷。The high-frequency arc starter is installed nearby to improve the success rate of arc ignition of the equipment, prevent tungsten clamping, tungsten electrode burning, etc., reduce the intensity of manual operation, and achieve the purpose of improving welding efficiency. At the same time, it reduces welding defects caused by abnormal arc starting.
本实施例实施后的经济收益:The economic benefits after the implementation of this embodiment:
原设备加工能力为壁厚5-40mm的奥氏体、铁素体、双相不锈钢等不锈钢及特种合金。焊接方式为P+T外焊,埋弧内、外焊。以产品8条焊缝为例,单班氩弧盖面5道次焊接1条焊缝,八个班次一支产品。The original equipment processing capacity is Austenitic, ferritic, duplex stainless steel and other stainless steels and special alloys with a wall thickness of 5-40mm. The welding method is P+T external welding, submerged arc internal and external welding. by
采用本实施例后,通过增加焊枪数量,提高生产效率,其中焊接方式P+T,改为P+T+T+T。After adopting this embodiment, the production efficiency is improved by increasing the number of welding torches, wherein the welding method P+T is changed to P+T+T+T.
采用本实施例后,加工能力提升,以φ3048*20*13500mm产品8条焊缝为例,单班可焊接4条焊缝,两班完成成品1支。满足P+T+T+T全自动焊接全工艺,也可实现单独操作。After adopting this embodiment, the processing capacity is improved. Taking 8 welds of φ3048*20*13500mm product as an example, 4 welds can be welded in a single shift, and 1 finished product can be completed in two shifts. Satisfies the whole process of P+T+T+T automatic welding, and can also be operated independently.
附:具体详见计算过程。Attachment: For details, see the calculation process.
计算过程:calculation process:
原机组年产能=((直径3048-壁厚20)×壁厚20×系数0.02491×长度13.5÷1000÷2÷8)×300天/年=685.8吨。The annual production capacity of the original unit = ((diameter 3048-wall thickness 20)×wall thickness 20×coefficient 0.02491×length 13.5÷1000÷2÷8)×300 days/year=685.8 tons.
现机组年产能=((直径3048-壁厚20)×壁厚20×系数0.02491×长度13.5÷1000÷2)×300天/年=2754吨。The annual production capacity of the current unit = ((diameter 3048-wall thickness 20)×wall thickness 20×coefficient 0.02491×length 13.5÷1000÷2)×300 days/year=2754 tons.
年产能增加产能=现机组产能-原机组年产能=2068.2吨。Annual capacity increase Capacity = current unit capacity - original unit annual capacity = 2068.2 tons.
说明:0.02491为不锈钢理算重量系数,按照每天8小时,年300天,加工利润5500元/吨,年产增加利润=年产能增加产能×5500元-增加1名操作工的工资=1137.5万元-10万=1127.5万元。合计:年增加产能利润:1127.5万元。Explanation: 0.02491 is the weight coefficient of stainless steel adjustment. According to 8 hours per day, 300 days per year, the processing profit is 5,500 yuan/ton, and the annual production increase profit = the annual production capacity increase capacity × 5,500 yuan - the salary of an additional operator = 11.375 million yuan -100,000 = 11.275 million yuan. Total: annual increase in production capacity profit: 11.275 million yuan.
本实施例对原有设备的改造,建成了一条高效、高质的智能化大口径不锈钢及特种合金焊管生产线,提高了生产效率,降低了企业的生产成本,创造了经济利润。In this embodiment, an efficient and high-quality intelligent large-diameter stainless steel and special alloy welded pipe production line has been built through the transformation of the original equipment, which improves the production efficiency, reduces the production cost of the enterprise, and creates economic profits.
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