CN115582604A - Gantry type multi-station welding system and method for large-diameter pipeline - Google Patents

Abstract

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

A large-caliber pipeline gantry-type multi-station welding system and welding method

technical field

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.

Background technique

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.

Contents of the invention

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.

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.

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

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.

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.

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.

Optionally, the welding components in the fixed welding device and the movable welding device both use TIG welding components.

Optionally, the length of the pipe is 1.5 meters, 2 meters or 3 meters.

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: 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: 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.

Compared with prior art, the beneficial effect of the present invention:

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. 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. 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. 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.

Description of drawings

Fig. 1 is the structural representation of welding system in the present embodiment;

Fig. 2 is a positional diagram of the welding torch assembly for welding 1.5 meters of pipelines in the present embodiment;

Fig. 3 is the positional relationship diagram of the welding torch assembly of welding 2 meters pipeline in the present embodiment;

Fig. 4 is a position relation diagram of the welding torch assembly for welding a 3-meter pipeline in this embodiment.

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.

detailed description

The present invention will be described in further detail below in conjunction with the accompanying drawings and embodiments.

Example

As shown in Figures 1 to 4, this embodiment provides a large-diameter pipeline gantry-type multi-station welding system, including a gantry 1, a lifting platform 11 is arranged on the gantry 1, and the lifting platform 11 is arranged along the axial direction of the pipeline 8 The linear guide rail 12 is fixedly installed, several sets of fixed welding devices are fixedly installed on the lifting platform 11 along the axis direction of the pipeline 8, and several sets of movable welding devices are slidably installed on the linear guide rail 12, and several groups of movable welding devices are slid to a suitable position and fixed by the locking mechanism respectively On the linear guide rail 12.

Through the above settings, several sets of welding devices are installed on the lifting table 11 and the linear guide rail 12, which can weld multiple circular seams at the same time to improve production efficiency; the linear guide rail 12 is fixed on the lifting table 11, and can synchronize the lifting table 11 Lifting, 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 12 to adjust the position, thereby being able to adapt to the circumferential seam welding of pipelines 8 of different lengths, which is easy to operate and saves cost. The locking mechanism can be locked by existing conventional locking parts, such as fasteners such as bolts.

The pipeline 8 in this embodiment can be stainless steel and special alloy pipelines.

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 welding torch assembly 21, The first welding torch assembly 21 is fixed on the lifting platform 11, the second welding torch device 3 includes an electric carriage 32 and a second welding torch assembly 31, the electric carriage 32 is fixed on the lifting platform 11, and the second welding torch assembly 31 is slidably arranged on the electric sliding carriage Rack 32.

Through the above setting, the second welding torch assembly 31 is slidably arranged on the electric carriage 32, which is convenient for adjusting the position of the first welding torch assembly 21 along the axial direction of the pipeline 8, so as to adapt to the circumferential seam welding of pipelines 8 of different lengths. The system automatically adjusts the position of the second welding torch assembly 31, which is convenient to operate, saves labor and has high efficiency.

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 pipeline 8, and can adapt to the welding of pipelines 8 of different lengths without horizontal adjustment, which saves costs.

In the gantry-type multi-station welding system for large-diameter pipelines in this embodiment, the movable welding device includes the electric cross large carriage 6, the electric cross small carriage 61 and the movable welding torch assembly, and the movable welding torch assembly is slidably mounted on the electric cross small carriage 61 On, the small electric cross carriage 61 is slidably installed on the large electric cross carriage 6.

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.

The large-diameter pipeline gantry-type multi-station welding system of this embodiment also includes a control system, the first welding torch assembly 21, the second welding torch assembly 31, the electric carriage 32, the electric cross carriage 6, and the electric cross carriage 61 and the movable welding torch assembly are electrically connected with the control system respectively. The control system controls the work of the first welding torch assembly 21, the second welding torch assembly 31 and the movable welding torch assembly. The control system controls the second welding torch assembly 31 to slide on the electric carriage 32. The control system controls the electric cross small carriage 61 to move on the electric cross. The slide frame 6 slides horizontally and vertically, and the control system controls the movable welding torch assembly to slide horizontally and vertically on the small electric cross slide frame 61 . The gantry-type multi-station welding system for large-diameter pipelines in this embodiment also includes a fixed frame 7 fixed on the ground, one end of the linear guide rail 12 is fixedly connected to the lifting platform 11, and the other end of the linear guide rail 12 passes through the spring balancer 71 Hang on the fixed frame 7.

Through the above setting, the setting of the fixed frame 7 is used to hang the linear guide rail 12, which reduces the gravity applied to the lifting table 11, the force of the linear guide rail 12 is more balanced and stable, and the lifting motion of the lifting table 11 is also more stable, thereby improving the welding device. welding stability.

In the large-diameter pipeline gantry-type multi-station welding system of this embodiment, the fixed frame 7 includes a frame surrounded by welding of several vertical pipes and several horizontal pipes, the upper end of the spring balancer 71 is connected to the upper part of the frame, and the lower end of the spring balancer 71 Connect to one end of the linear slide rail.

Through the above setting and the setting of the spring balancer 71, the other end of the linear guide rail 12 is suspended on the fixed frame 7, so that the linear guide rail 12 is balanced in force, and moves up and down synchronously with the lifting table 11. The structure is simple and several groups of welding are realized. The synchronous lifting of the device is suitable for welding of pipes 8 with different pipe diameters, and the operation is convenient, and the stability of the linear guide rail 12 is improved.

Specifically, a 150*100 square tube support frame is added to the other side of the lifting platform 11, and a 120*120 square tube is installed at the center end of the platform of the original gantry to support the sliding mechanism of the other three welding torches. A linear guide rail 12 is installed on the platform end to facilitate the adjustment of the middle line of the welding torch. The other side of the linear guide rail 12 is equipped with a suitable spring balancer 71 to ensure that the linear guide rail 12 can go up and down stably with the lifting platform 11 without increasing the weight of the original equipment.

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.

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 welding torch device 4 and the fourth welding torch device 5 . The movable welding torch assembly of the third welding torch device 4 is the third welding torch assembly 41 , and the movable welding torch assembly of the fourth welding torch device 5 is the fourth welding torch assembly 51 .

In the gantry-type multi-station welding system for large-diameter pipelines in this embodiment, the length of the pipeline 8 is 1.5 meters, 2 meters or 3 meters.

Specifically, as shown in Figure 2, when the length of the pipeline 8 is 1.5 meters, the distance between the first welding torch assembly 21, the second welding torch assembly 31, the third welding torch assembly 41 and the fourth welding torch assembly 51 is 1.5 meters. meters, four girth welds can be welded at the same time.

As shown in Figure 3, when the length of pipeline 8 was 2 meters, the interval distance between the second welding torch assembly 31 and the first welding torch assembly 21 was adjusted to be 2 meters, and the distance between the third welding torch assembly 41 and the second welding torch assembly 31 was adjusted. The spacing distance is 2 meters, adjust the fourth welding torch device 5 to slide on the linear guide rail 12, and adjust the position of the fourth welding torch assembly 51 on the electric cross carriage until the distance between the fourth welding torch assembly 51 and the third welding torch assembly 41 The spacing is 2 meters so that four welds can be welded simultaneously.

As shown in Figure 4, when the length of the pipeline 8 is 3 meters, the distance between the third welding torch assembly 41 and the first welding torch assembly 21 is adjusted to be 3 meters, the fourth welding torch device 5 is adjusted to slide on the linear guide rail 12, and the first welding torch assembly 41 is adjusted to slide on the linear guide rail 12. The position of the four welding torch assemblies 51 on the electric cross slide until the distance between the fourth welding torch assembly 51 and the third welding torch assembly 41 is 3 meters, start the first welding torch assembly 21, the third welding torch assembly 41 and the fourth welding torch assembly 51, three welds can be welded at the same time.

The welding method to the large diameter stainless steel and special alloy pipeline 8 in the present embodiment is as follows:

S1: Adjust the height of the lifting table 11 through the control system to adapt to the diameter of the pipeline 8, adjust the positions of the first welding torch assembly 21, the electric cross carriage 61, and the second welding torch assembly 31 through the control system to adapt to the length of the pipeline 8, so that A group of welding devices are correspondingly arranged between every two adjacent pipelines 8;

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 pipeline 8 .

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

Take 8 welds of the product as an example, 4 welds can be welded in a single shift, and 1 finished product can be completed in two shifts.

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.

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.

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.

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.

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.

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.

The economic benefits after the implementation of this embodiment:

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

Take 8 welds of a product as an example, one weld is welded in 5 passes of the argon arc cover in a single shift, and one product is welded in eight shifts.

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.

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.

Attachment: For details, see the calculation process.

calculation process:

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.

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.

Annual capacity increase Capacity = current unit capacity - original unit annual capacity = 2068.2 tons.

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.

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.

Claims (8)

1. The utility model provides a heavy-calibre pipeline planer-type multistation welding system, a serial communication port, including portal frame (1), set up elevating platform (11) on portal frame (1), set up linear guide (12) along pipeline (8) axial fixity on elevating platform (11), the fixed welding set of a plurality of groups along the axis direction of pipeline (8) is gone up in elevating platform (11), it sets up a plurality of groups of movable welding set to slide on linear guide (12), a plurality of groups of movable welding set slide to fix on linear guide (12) through locking mechanical system respectively after the suitable position.

2. The gantry type multi-station welding system for the large-caliber pipelines according to claim 1, wherein the fixed welding devices are arranged in two groups, namely a first welding gun device (2) and a second welding gun device (3); first welder device (2) includes first welder subassembly (21), and first welder subassembly (21) is fixed on elevating platform (11), and second welder device (3) includes electronic balladeur train (32) and second welder subassembly (31), and electronic balladeur train (32) are fixed on elevating platform (11), and second welder subassembly (31) slides and sets up on electronic balladeur train (32).

3. The gantry type multi-station welding system for the large-caliber pipelines according to claim 2, wherein the movable welding device comprises an electric large cross carriage (6), an electric small cross carriage (61) and a movable welding gun assembly, the movable welding gun assembly is slidably mounted on the electric small cross carriage (61), and the electric small cross carriage (61) is slidably mounted on the electric large cross carriage (6).

4. The gantry type multi-station welding system for the large-caliber pipelines according to claim 3, further comprising a control system, wherein the first welding gun assembly (21), the second welding gun assembly (31), the electric carriage (32), the electric cross large carriage (6), the electric cross small carriage (61) and the movable welding gun assembly are respectively electrically connected with the control system.

5. The gantry type multi-station welding system for the large-diameter pipelines according to any one of claims 1 to 4, further comprising a fixed frame (7) fixed on the ground, wherein one end of the linear guide rail (12) is fixedly connected to the lifting table (11), and the other end of the linear guide rail (12) is suspended on the fixed frame (7) through a spring balancer (71).

6. The gantry type multi-station welding system for the large-caliber pipelines according to claim 5, wherein the fixed frame (7) comprises a frame formed by welding a plurality of vertical pipes and a plurality of transverse pipes, the upper end of the spring balancer (71) is connected to the upper part of the frame, and the lower end of the spring balancer (71) is connected to one end of a linear sliding rail.

7. Gantry-type multi-station welding system for large-caliber pipes according to any one of claims 1 to 4, wherein the length of the pipe (8) is 1.5, 2 or 3 meters.

8. A large-caliber pipeline welding method comprising the large-caliber pipeline gantry type multi-station welding system of any one of claims 4 to 7, and the method is characterized by comprising the following steps of:

s1: the height of the lifting platform (11) is adjusted through the control system to adapt to the caliber of the pipeline (8), and the positions of the second welding gun assembly (31), the electric sliding frame (32), the electric cross large sliding frame (6), the electric cross small sliding frame (61) and the movable welding gun assembly are adjusted through the control system to adapt to the length of the pipeline (8), so that a group of welding devices is correspondingly arranged between every two adjacent pipelines (8);

s2: one or more groups of welding devices are controlled by the control system to weld the circular seams of the pipelines (8) at the same time.

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