CN116060852A

CN116060852A - Welding machine in pipeline

Info

Publication number: CN116060852A
Application number: CN202310194157.1A
Authority: CN
Inventors: 邱文虎; 黄菲; 罗明洪; 邹志祥; 杨志梅; 李硕; 张德杰
Original assignee: CHENGDU XIONGGU JIASHI ELECTRICAL CO LTD
Current assignee: CHENGDU XIONGGU JIASHI ELECTRICAL CO LTD
Priority date: 2023-03-02
Filing date: 2023-03-02
Publication date: 2023-05-05

Abstract

The invention discloses an in-pipeline welding machine which comprises a machine head, a machine body and a first connecting mechanism, wherein the machine head is provided with a tensioning mechanism and a welding mechanism, the machine body is provided with a running system for running in a pipeline, the machine head is connected with the machine body through the first connecting mechanism, and the first connecting mechanism has controllable movable degree of freedom so that the machine head and the machine body can deflect relatively. The machine head in the pipeline inner welding machine can deflect relative to the machine body, so that the whole pipeline inner welding machine is bent, the pipeline inner welding machine can smoothly pass through the bent pipe section of the pipeline, the pipeline inner welding machine can adapt to bent pipelines with different bending radiuses, the bending capacity is effectively improved, and the application range is wide.

Description

Welding machine in pipeline

Technical Field

The invention relates to the technical field of welding equipment, in particular to an internal pipeline welding machine.

Background

The welding machine in the pipeline is widely applied to pipeline construction of petrochemical industry, electric power, coal, water delivery and the like, and is mainly used for butt joint of two pipelines and internal root welding. Pipelines paved in various fields are generally required to adapt to environmental terrains, so that the pipelines are generally provided with slopes and bending conditions, particularly in mountain areas, the slopes of the pipelines are larger, the bending radius is smaller, the slopes of the pipelines can reach more than 25 degrees, even the local slopes exceed 45 degrees, the bending radius of the pipelines is minimum to reach 6D (D refers to the outer diameter of the pipelines), the existing pipeline internal welding machine is low in terrain adaptability, poor in passing performance, limited in climbing capacity and poor in bending capacity, the pipeline internal welding machine itself has a certain length and can only pass through a bending pipe section with a larger bending radius, the condition that the pipeline internal welding machine is clamped in the bending pipe section when the pipeline internal welding machine moves to the bending pipe section with a smaller bending radius cannot normally pass through the bending pipe section with a smaller bending radius, pipeline butt joint and welding connection cannot be realized on the bending pipe section, and the applicability is poor.

Disclosure of Invention

The invention aims to solve the technical problems and the technical task of improving the prior art, provides an in-pipeline welding machine, and solves the problems that the traditional in-pipeline welding machine in the prior art is poor in bending capability and difficult to butt joint and weld connection of pipelines on bent pipe sections.

In order to solve the technical problems, the technical scheme of the invention is as follows:

an in-pipeline welding machine comprises a machine head, a machine body and a first connecting mechanism;

the machine head is provided with a tensioning mechanism and a welding mechanism;

the machine body is provided with a traveling system for traveling in the pipeline;

the machine head is connected with the machine body through a first connecting mechanism, and the first connecting mechanism has controllable movable degree of freedom so that the machine head and the machine body can deflect relatively.

The pipeline internal welding machine is connected between the machine head and the machine body through the deflectable first connecting mechanism, so that the machine head can deflect relative to the machine body, the integral bending form of the pipeline internal welding machine is changed when the pipeline internal welding machine passes through the bent pipe section of the pipeline, and the deflection angle of the machine head relative to the machine body is adjustable, so that the pipeline internal welding machine can flexibly adapt to the bent pipe sections with different bending radiuses, can smoothly pass through the bent pipe sections, avoids the condition that the pipeline internal welding machine is clamped on the bent pipe sections, effectively improves the overbending capacity of the pipeline internal welding machine, and can better adapt to the requirements of different terrains.

Further, the first connecting mechanism comprises a static end and a movable end, the static end is connected with the machine body, the movable end is connected with the machine head, and a plurality of movable members are arranged between the static end and the movable end in parallel so that the static end and the movable end can move relatively. The invention adopts the moving end of the parallel structure as the first connecting mechanism, can realize the movable adjustment of multiple degrees of freedom, meets the requirement of the welding machine in the pipeline for passing through various bent pipe sections, and the first connecting mechanism is an active movable adjusting structure, enables the relative deflection of the static end and the moving end to be actively adjustable by controlling the change of each movable component, and can stably keep the static end and the moving end in a relative deflection state, thereby being capable of carrying out accurate active adjustment according to the bending radius, the bending direction and the like of the bent pipe sections and enabling the welding machine in the pipeline to pass along the bent pipe sections better.

Further, the movable component is a linear telescopic component, one end of the linear telescopic component is movably connected with the static end, and the other end of the linear telescopic component is movably connected with the movable end. The structure is simple and compact, the relative deflection state between the static end and the movable end can be controlled by controlling the expansion and contraction amount of each linear expansion member, the control is easy, and the control precision is high.

Further, the first connecting mechanism is a parallel moving mechanism or a serial moving mechanism, the first connecting mechanism has two degrees of freedom to six degrees of freedom, the flexibility is high, deflection and even translation of the machine head relative to the machine body can be realized, the posture of the machine head relative to the machine body can be flexibly and accurately regulated, and the passing performance of the welding machine in the pipeline can be better improved.

Further, the machine head comprises a sensor which is arranged on the machine head and used for detecting a pipeline, the control system receives data which are detected and collected by the sensor and analyzes and processes the data to obtain control parameters, and the first connecting mechanism acts according to the control parameters to adjust the pose of the machine head. The sensor is used for detecting the condition of the pipeline so as to determine the pose state of the machine head relative to the pipeline, so that the pose of the machine head is adjusted through the first connecting mechanism to adjust the machine head to an accurate pose for bending or welding operation, the automation degree is improved, the welding machine in the pipeline can automatically adjust the pose according to the specific condition of the pipeline for bending, and the tensioning mechanism and the welding mechanism on the machine head can be accurately aligned with the welding seam area of the pipeline port, so that the welding quality is improved.

Further, the sensors are arranged on the machine head at intervals along the circumference, and the central axis of the circumference where the sensors are arranged coincides with the central axis of the tensioning mechanism. The pipeline is detected at a plurality of positions in the circumferential direction through the sensors, the analysis and the treatment are carried out on the data detected and collected by the sensors, the pose state of the tensioning mechanism and the welding mechanism relative to the pipeline can be more accurately known, the pose of the machine head is more accurately adjusted, the tensioning mechanism and the welding mechanism are accurately matched with the pipeline, and then the welding precision and quality are improved.

Further, the sensor is a stripe type laser displacement sensor for detecting and collecting pipeline profile data. The strip-shaped laser displacement sensor emits strip-shaped laser strips to irradiate on the pipeline, and particularly comprises an inner wall of the pipeline and a groove at the end part of the pipeline, so that a laser contour line is formed on the pipeline, the sensor detects that collected laser contour line images are pipeline contour data, different laser contour line images can be formed when the position and the gesture of a machine head are different relative to the pipeline, the gesture of the machine head relative to the pipeline can be determined through analyzing and processing the laser contour line images, and the machine head can be adjusted to the most accurate gesture through controlling the first connecting mechanism.

Further, the control system comprises a coaxial unit, the coaxial unit is used for analyzing and processing data acquired by the sensor to obtain control parameters for coaxiality, and the first connecting mechanism acts according to the control parameters for coaxiality to enable the central axis of the welding mechanism on the machine head to coincide with the central axis of the pipeline at the position of the pipeline where the welding mechanism is located. According to the data detected and collected by the sensor, the position and the posture of the machine head are automatically controlled by the first connecting mechanism, the machine head is kept in a state that the central axis of the welding mechanism coincides with the central axis of the pipeline so as to realize coaxial overbending, when the pipe section passes through the pipe section, the machine head needs to synchronously deflect so as to keep the state that the central axis of the welding mechanism coincides with the central axis of the pipeline, the first connecting mechanism acts according to the data detected and collected by the sensor so as to deflect the machine head to keep the state that the central axis of the welding mechanism coincides with the central axis of the pipeline, the deflection posture of the machine head relative to the machine body is automatically adjusted when the welding machine in the pipeline passes through the pipe section, the whole shape of the welding machine in the pipeline is changed into a bent shape, the welding machine in the pipeline can smoothly pass through the pipe section is ensured, and the overbending capacity is improved.

Further, the control system comprises an abutting unit, the abutting unit analyzes and processes the acquired data detected by the sensor to obtain control parameters for abutting, and the first connecting mechanism acts according to the control parameters for abutting so that the welding mechanism is opposite to the center of a welding seam between two pipelines to be abutted. The gesture of aircraft nose is adjusted with realizing automatic alignment to first coupling mechanism according to the data that the sensor detects the collection, and first coupling mechanism's action precision is high, can improve alignment precision and alignment efficiency.

Further, the docking unit includes:

the scene judging module is used for analyzing and processing the data acquired by the sensor to judge whether the data are in the opposite scene of the end part of the pipeline acquired by the sensor;

the metering module analyzes and processes the data acquired by the sensor to obtain the distance from the sensor to the plane where the end part of the pipeline is positioned when the metering module is in the opposite scene;

the parking module sends out an instruction for controlling a walking system to park a machine body when the distance from the sensor to the plane where the end part of the pipeline is positioned reaches a walking stopping condition;

and the contra-opening fine adjustment module is used for analyzing and processing the data acquired by the sensor in the machine body parking state to obtain control parameters for fine adjustment, and the first connecting mechanism acts according to the control parameters for fine adjustment so that the welding mechanism is opposite to the center of a welding seam between two pipelines to be butted.

When two pipelines to be butted are welded and connected, if welding quality is to be ensured, a welding gun of a welding unit of a welding mechanism needs to accurately face the center of a welding seam between the two pipelines, the action precision of a running system on a machine body is low, the welding mechanism is difficult to accurately align to the center of the welding seam only through the controlled stop position of the running system, and the action precision of a first connecting mechanism is high, so that when a sensor detects and collects the end part of the pipeline, the running system is controlled to integrally stop the welding machine in the position of the pipeline close to the welding seam, specifically, the parking position of the running system is controlled by detecting the distance from the sensor to the plane where the end part of the pipeline is located, and then the pose of the machine head is accurately adjusted by using the first connecting mechanism under the stop state of the machine body of the welding machine in the pipeline, so that the welding mechanism accurately faces the center of the welding seam, the degree of automation is high, manual intervention is not needed, the mouth alignment precision is high, and the welding connection quality can be effectively improved.

Further, the traveling system comprises a traveling mechanism, the traveling mechanism comprises a plurality of traveling wheel assemblies which are arranged at intervals along the circumferential direction of the machine body, and the traveling wheel assemblies are connected to a jacking mechanism arranged on the machine body. Simple structure, easy to carry out, advancing mechanism mainly used drive organism is advanced along the pipeline inner wall, and with the tight mechanism of top with walking wheel subassembly compress tightly on the pipeline inner wall, can stably drive welding machine in the whole pipeline to advance along the pipeline when guaranteeing walking wheel subassembly operation, improve the climbing ability of welding machine in the pipeline, avoid appearing skidding, swift current car's situation, can be applicable to the slope pipeline section of heavy grade.

Further, the walking wheel assembly is provided with two walking wheel assemblies and is distributed on two sides of the machine body in the diameter direction, and the jacking mechanism is a jacking hydraulic cylinder connected between the walking wheel assemblies on two sides. The hydraulic jacking device has the advantages that the hydraulic jacking device is simple and compact in structure, the distance between the two traveling wheel assemblies is adjusted through the hydraulic jacking cylinder, so that the traveling wheel assemblies are pressed on the inner wall of a pipeline, the hydraulic jacking force is provided by the hydraulic jacking cylinder, the jacking force can be improved under the condition that the volume is not increased, and the advancing stability of a welding machine in the pipeline along the pipeline is ensured.

Further, each traveling wheel assembly is respectively provided with a traveling motor, so that each traveling wheel assembly can independently perform operation control, the rotating speed of each traveling wheel assembly can be flexibly adjusted according to requirements, and particularly when the traveling wheel assembly is in over-bending, the traveling speed of the traveling wheel assembly positioned at the inner side of the bent pipe section is lower than that of the traveling wheel assembly positioned at the outer side of the bent pipe section, the over-bending reliability is improved, the situation that a welding machine in a pipeline is blocked in the bent pipe section is avoided, and the traveling motor is prevented from being damaged due to overlarge resistance.

Further, the traveling system comprises a brake mechanism, the brake mechanism comprises a brake cylinder, a brake block and a retaining elastic piece, the brake block is driven by the brake cylinder to switch between a brake position and a release position, and the brake block is further connected with the retaining elastic piece for driving the brake block to be retained at a brake position. The brake reliability is improved, even if the brake cylinder is damaged and does not work, the brake pad can still be kept in a state of propping against the brake position inside the pipeline under the action of the elastic piece, the situation of sliding is avoided, the welding machine in the pipeline can be stably stopped at the pipeline with a larger gradient, and the reliability and the safety are improved.

Further, the traveling system comprises a flexible wheel assembly, the flexible wheel assembly comprises wheels, a wheel seat and an elastic assembly, the wheels are arranged on the wheel seat, the wheel seat is hinged on the machine body, the rotating plane of the wheel seat is along the radial direction of the machine body, and the elastic assembly is connected between the wheel seat and the machine body. The wheel in the flexible wheel subassembly can cushion flexible in the radial of organism for the organism, receives external force effort when pipeline interior welding machine, and for example, the tight mechanism work of rising is supported and is leaned on pipeline inner wall or aircraft nose and pipeline inner wall and take place the contact collision when, and the wheel can deflect and then make elastic component take place elastic deformation for the organism along with the wheel seat, utilizes elastic component buffering to absorb impact effort, can avoid pipeline interior welding machine to receive the impact and impaired, plays the effect of effectively protecting pipeline interior welding machine.

Further, the flexible wheel assembly further comprises an angle adjusting motor which is arranged on the wheel seat and connected with the wheels, and the angle adjusting motor is used for steering and adjusting the travelling direction of the wheels. In-pipeline welding machine is difficult to guarantee in-pipeline welding machine's the constant invariable gesture along the in-pipeline welding machine's in-process that the pipeline inner wall marched, unavoidable in-pipeline welding machine can take place rotatory situation for the pipeline, drives the wheel through the angle modulation motor and turns to for in-pipeline welding machine rotates for the pipeline, and then makes in-pipeline welding machine resume required gesture.

Further, the device also comprises a battery unit, wherein the battery unit supplies power for the tensioning mechanism, the welding mechanism, the traveling system and the first connecting mechanism. The integrated level is high, the power is intensively supplied through the battery unit, and the application of the welding machine in the pipeline is more flexible.

Further, the machine body is divided into a plurality of sections along the axis direction of the pipeline, and adjacent sections are connected through a second connecting mechanism, and the second connecting mechanism is a deflectable connecting mechanism. The machine body with a certain length originally is divided into a plurality of sections, and the adjacent sections can deflect relatively through the second connecting mechanism, so that the machine body can bend and deform, the welding machine in the pipeline can bend the pipe section with smaller bending radius, and the bending capacity of the welding machine in the pipeline is further improved.

Further, the second connecting mechanism comprises a first end, a second end, a universal joint and a flexible connecting piece, wherein the universal joint and the flexible connecting piece are connected between the first end and the second end, a plurality of flexible connecting pieces are distributed on the circumference of the universal joint, the first end is connected with the previous section, and the second end is connected with the latter section. The structure is simple, the implementation is easy, the second connecting mechanism is a passive deflection connecting structure, active adjustment is not needed, when the welding machine in the pipeline passes through the bent pipe section, each section of the machine body can be respectively contacted with the inner wall of the pipeline, under the action of the abutting force of the inner wall of the pipeline on each section, the adjacent sections are deflected relatively through the second connecting mechanism to match the bending radius of the bent pipe section, so that the machine body is passively converted into a bending form matched with the bending radius of the bent pipe section, and the welding machine in the pipeline can smoothly pass through the bent pipe section.

In order to improve the flexibility of the operation of the internal welding machine in a pipeline in the prior art, the internal welding machine is arranged into a plurality of sections and connected through universal joints to improve the bending capacity, but the internal welding machine is influenced by the inner peripheral surface of the pipeline in the process, spiral rotation can occur during the operation in the pipeline, and the initial welding position of a welding head on a welding assembly of the internal welding machine is changed, so that the lap joint quality and the construction efficiency of a welding seam are influenced, manual quantitative adjustment is generally required, and the operation gesture has low controllable precision and low efficiency.

The invention provides a posture adjusting system of an internal welding machine,

comprises a gesture adjusting device, a sensor and an electrical control module, wherein the gesture adjusting device is arranged between a first section and a second section of the internal welding machine,

the gesture adjusting device comprises a movable platform, a fixed platform and a linear driving mechanism, wherein the movable platform is connected with the first section, the fixed platform is connected with the second section, and two ends of the linear driving mechanism are respectively and movably connected with the movable platform and the fixed platform;

the sensor is used for acquiring pipeline profile data of the circumference of the movable platform on the first section;

the linear driving mechanism is connected with an electric control module, and the electric control module is used for calculating the target gesture of the first section according to the pipeline profile data and adjusting the linear driving mechanism to enable the axis of the movable platform on the first section to be in the target gesture.

Further, the gesture adjusting device also comprises a movable end mounting seat and a fixed end mounting seat,

the movable end mounting seat is fixed on the movable platform through bolts, one end of the linear driving mechanism is detachably connected to the movable end mounting seat through a universal joint,

the fixed end mounting seat is fixed on the fixed platform through bolts, and the other end of the linear driving mechanism is detachably connected to the fixed end mounting seat through a universal joint.

Further, the posture adjusting device is a six-degree-of-freedom motion platform comprising six linear driving mechanisms.

Further, the plurality of sensors are provided, and all the sensors are uniformly distributed in the first section along the circumferential direction of the first section.

Further, the sensor is a stripe laser sensor, and the sensor is used for acquiring a laser contour line projected on the inner peripheral surface of the pipeline to obtain pipeline contour data of the peripheral side of the first section rising unit.

Further, the electrical control module includes:

the motion controller is used for calculating the target gesture of the first section according to the pipeline profile data and calculating a motion inverse solution algorithm for the target gesture to generate a length change signal of the linear driving mechanism;

The servo driver is used for generating a corresponding pulse signal according to the length change signal issued by the motion controller;

and the servo motor is used for rotating according to the pulse signals issued by the servo driver so as to drive the corresponding linear driving mechanism to perform telescopic movement until the first section is in the target posture.

An attitude adjustment method of an internal welding machine based on the system, for adjusting a positional relationship between a first section and a second section of the internal welding machine, comprises:

collecting pipeline profile data of the circumference side of the movable platform on the first section;

calculating a target attitude of the first section according to the pipeline profile data, and generating an adjusting signal based on the target attitude calculation;

and driving the linear driving mechanism based on the adjusting signal to enable the axis of the movable platform on the first section to be in a target posture.

Further, the step of calculating the target gesture of the first section according to the pipeline profile data and generating the adjustment signal based on the target gesture calculation specifically includes:

based on known sensor installation correction coefficients, converting contour data obtained by scanning each sensor into correction contour data under a first sectional coordinate system;

Calculating the position and posture information of the current pipeline under the first sectional coordinate system based on the corrected contour data;

and calculating to obtain the target gesture of the first section based on the pipeline gesture information, and generating an adjusting signal based on the target gesture calculation.

The present application also provides a storage medium having stored thereon a computer program which, when executed, implements the steps performed by the posture adjustment method of an internal welding machine described above.

The application also provides an internal welding machine, comprising: a first section, a second section, and an attitude adjustment system;

the gesture adjusting system comprises a gesture adjusting device, an electrical control module and a sensor;

the gesture adjusting device is arranged between the first section and the second section; the gesture adjusting device comprises a moving platform, a fixed platform, a linear driving mechanism and a universal joint, wherein the moving platform and the first-section frame are of an integrated structure, the fixed platform and the second-section frame are of an integrated structure, and two ends of the linear driving mechanism are respectively connected with the moving platform and the fixed platform through the universal joint;

The electrical control module is used for calculating the target gesture of the first section according to the pipeline profile data and resolving the target gesture to generate a length change signal of the linear driving mechanism; the electrical control module is also used for controlling the linear driving mechanism to conduct telescopic movement by utilizing the length change signal so as to enable the first section to be in the target posture.

The application provides a posture adjustment system of an internal welding machine, which comprises a first section, a second section and a posture adjustment device, wherein the posture adjustment device is arranged between the first section and the second section; the gesture adjusting device comprises a moving platform, a fixed platform, a linear driving mechanism and a universal joint, wherein the moving platform and the first-section frame are of an integrated structure, the fixed platform and the second-section frame are of an integrated structure, and two ends of the linear driving mechanism are respectively connected with the moving platform and the fixed platform through the universal joint; the sensor is used for collecting pipeline profile data of the position of the inner welding machine movable platform; the electrical control module is used for calculating the target gesture of the first section according to the pipeline profile data, and calculating the target gesture by a motion inverse solution algorithm to generate a length change signal of the linear driving mechanism; the electrical control module is also used for controlling the linear driving mechanism to conduct telescopic movement by utilizing the length change signal so as to enable the first section to be in the target posture.

The application provides a posture adjustment device sets up between interior welding machine's first section and second section, and above-mentioned posture adjustment device includes movable platform, fixed platform, straight line actuating mechanism and universal joint. Because the movable platform and the first-section frame are of an integrated structure, and the fixed platform and the second-section frame are of an integrated structure, when the linear driving mechanism of the posture adjusting device performs telescopic movement, the posture of the first section can be changed. In the working process, the electric control module calculates the target attitude of the first section according to the pipeline profile data, calculates the target attitude by a motion inverse solution algorithm to generate a length change signal of the linear driving mechanism, and controls the linear driving mechanism to perform telescopic motion through the length change signal so that the first section is in the target attitude. According to the method and the device, automatic adjustment of the posture of the internal welding machine can be achieved according to the pipeline contour data, and welding quality is improved. The application also provides a posture adjusting method of the internal welding machine, a storage medium and the internal welding machine, and the method has the beneficial effects.

When an inner welding machine works on the bent pipe, the inner welding machine is extremely easy to generate the condition that the welding position and the welding line position of the pipeline groove deviate greatly due to the change of the shape of the pipeline, the alignment precision is low, manual adjustment by a worker is often needed, the dead weight of the inner welding machine is heavy, long adjustment time is often needed through manual adjustment by the worker, and the operation is inconvenient.

The application provides an internal welding machine alignment method, which comprises the following steps:

detecting Zhou Ceguan-channel profile data of the welding unit of the internal welding machine, and judging whether the end face of the pipeline is detected or not based on the pipeline profile data;

when the sensor for detecting the pipeline profile data and the plane where the end face of the pipeline is positioned meet the preset distance, controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline;

and calculating the position relation between the sensor and the end face of the pipeline to obtain pose information, and adjusting the multi-degree-of-freedom adjusting mechanism between the conical head mechanism and the machine body mechanism of the internal welding machine through the pose information, so that a welding unit on the conical head mechanism of the internal welding machine is opposite to a groove to be welded, and the internal welding machine and the pipeline are relatively fixed.

Further, the step of detecting the profile data of the welding unit Zhou Ceguan of the inner welding machine includes:

acquiring pipeline profile data by a sensor on a conical head mechanism of the internal welding machine,

binarizing the pipeline profile data to obtain a profile image, and comparing the profile image with a preset groove profile image;

and judging whether the end face of the pipeline is detected according to the comparison result.

Further, the sensor is a stripe type laser displacement sensor, and the sensor is used for obtaining pipeline profile data containing pipeline inner peripheral surface or pipeline end surface data through linear laser scanning.

Further, when the sensor for detecting the pipeline profile data and the plane where the end face of the pipeline is located meet a preset distance, the step of controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline comprises the following steps:

when the end face of the pipeline is detected and the matching result is more than 1,

and calculating whether the position relation between the sensor and the plane where the end face of the pipeline is positioned reaches a preset distance relation, and controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline when the position relation is satisfied, so that the welding unit is stopped in the groove area.

Further, before the step of controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline, the method further comprises the following steps:

processing the pipeline profile data to obtain a coarse translation and coarse rotation value of the pipeline profile compared with the cone head mechanism;

the multi-degree-of-freedom platform is adjusted to enable the central axis of the welding unit to be coaxial with the central axis of the peripheral side pipeline.

Further, the calculating the position relation between the sensor and the end face of the pipeline to obtain pose information includes:

acquiring contour data of a pipeline to obtain a contour image, and detecting corner points; obtaining rough difference coordinate values of each vertex of the contour image;

taking the rough difference coordinate value of each vertex of the contour image as an initial value, and performing groove contour shape fitting on the contour data to obtain the accurate coordinate of each vertex of the contour;

Converting the accurate coordinates of each vertex of the profile into groove feature space coordinates under a cone head mechanism coordinate system;

calculating the position and the posture of the circle where the current groove is positioned under a cone head mechanism coordinate system through groove feature point space coordinates;

and obtaining pose information, wherein the pose information comprises deflection angle and offset data existing between the groove and the cone head mechanism.

Further, the step of performing groove contour shape fitting on the contour data to obtain accurate coordinates of each vertex of the contour includes:

constructing a groove contour mathematical model corresponding to the contour data by taking the coordinates of the angular points as initial values;

and solving the contour mathematical model by utilizing an optimized objective function of a least square method to obtain the accurate coordinates of each vertex of the contour.

Further, the step of adjusting the multi-degree-of-freedom adjusting mechanism between the taper head mechanism and the machine body mechanism of the internal welding machine through the pose information to enable a welding unit on the taper head mechanism of the internal welding machine to be opposite to a groove to be welded and enable the internal welding machine and the pipeline to be fixed relatively comprises the following steps:

according to the pose information, a multi-degree-of-freedom adjusting mechanism between a conical head mechanism and a machine body mechanism of the internal welding machine is adjusted, and a welding torch in a welding unit on the conical head mechanism is opposite to a groove through the expansion and contraction amount of one or more electric cylinders in the multi-degree-of-freedom adjusting mechanism in adjustment;

After the position and the posture of the cone head mechanism are adjusted, the tensioning mechanism stretches out to enable the inner welding machine and the pipeline to be relatively fixed.

The application also provides an interior welding machine is to mouthful device, includes the tight unit that rises that distributes along interior welding machine aircraft nose circumference, still includes:

the sensor is used for detecting outline data of the welding unit Zhou Ceguan channels of the internal welding machine and judging whether the end face of the pipeline is detected or not based on the outline data;

the control system is used for controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline when the sensor for detecting the profile data and the plane where the end face of the pipeline is positioned meet the preset distance;

the control system is also used for calculating the position relation between the sensor and the end face of the pipeline to obtain pose information, and the multi-degree-of-freedom adjusting mechanism between the conical head mechanism and the machine body of the internal welding machine is adjusted through the pose information, so that a welding unit on the conical head mechanism of the internal welding machine is opposite to a groove to be welded, and the internal welding machine and the pipeline are relatively fixed.

The application also provides an internal welding machine, which comprises a conical head mechanism, a machine body mechanism, a sensor, a multi-degree-of-freedom adjusting mechanism, a memory and a processor, wherein the sensor is arranged on the conical head mechanism, the multi-degree-of-freedom adjusting mechanism is arranged between the conical head mechanism and the machine body mechanism, a computer program is stored in the memory, and the processor realizes the steps of the internal welding machine alignment method when calling the computer program in the memory.

The application also provides a storage medium, on which a computer program is stored, which when executed, implements the steps performed by the butt-joint method of the internal welding machine.

The application provides an internal welding machine alignment method, the internal welding machine including set up in the sensor of conical head mechanism, and set up in multi freedom adjustment mechanism between conical head mechanism and the fuselage mechanism, the internal welding machine alignment method includes: collecting pipeline profile data by using the sensor, determining a target stop position by using the pipeline profile data, and controlling the internal welding machine to move to the target stop position; when the internal welding machine moves to the target stop position, a welding unit in the conical head mechanism moves to a groove area; determining a groove characteristic point according to the pipeline profile data, and determining groove pose information of a pipeline groove in a cone head mechanism coordinate system according to the space coordinate of the groove characteristic point in the cone head mechanism coordinate system; the multi-degree-of-freedom adjusting mechanism is utilized to adjust the pose of the cone head mechanism according to the groove pose information, so that a welding torch of the welding unit is opposite to the center of a welding seam of the pipeline groove; and executing pipeline opening operation at the position corresponding to the pipeline groove.

According to the bevel head mechanism, the multi-degree-of-freedom adjusting mechanism is used for adjusting the pose of the bevel head mechanism according to the bevel pose information, so that a welding torch of a welding unit is opposite to the center of a welding line of a pipeline bevel. Through the mode, the welding torch of the welding unit of the internal welding machine can be automatically adjusted to the position opposite to the center of the welding line of the groove of the pipeline under the butt-joint scene, so that the internal welding machine realizes high-precision automatic butt-joint, and further the welding quality is improved. The application also provides an internal welding machine alignment device, a storage medium and an internal welding machine, and the internal welding machine alignment device has the beneficial effects and is not repeated here.

Compared with the prior art, the invention has the advantages that:

the machine head in the pipeline inner welding machine can deflect relative to the machine body, so that the whole pipeline inner welding machine is subjected to bending morphological change, the pipeline inner welding machine can smoothly pass through the bent pipe section of the pipeline, the pipeline inner welding machine can adapt to bent pipelines with different bending radiuses, the bending capacity is effectively improved, and the requirements of different terrains are flexibly met;

the first connecting mechanism is an active movable adjusting structure, so that the deflection gesture of the machine head relative to the machine body can be actively adjusted, and the machine head can pass through the bent pipe section more smoothly and without blocking;

The automatic welding machine has the advantages that the automatic degree is high, manual intervention is not needed, the posture of the machine body can be automatically adjusted according to the pipeline condition so as to realize automatic overbending, automatic butt welding can be realized, a welding mechanism is accurately opposite to the center of a welding seam, the butt welding efficiency is high, the accuracy is high, and the welding quality is further improved.

Drawings

FIG. 1 is an overall schematic diagram of an in-line welder of the present invention;

FIG. 2 is a schematic top view of FIG. 1;

FIG. 3 is a schematic view of a tensioning mechanism and a welding mechanism disposed on a machine head;

FIG. 4 is a structural view of a welding unit;

FIG. 5 is a schematic diagram of the tensioning and welding mechanisms on the machine head in cooperation with two pipes to be butted;

FIG. 6 is a schematic view of a first connection mechanism;

FIG. 7 is a schematic view of another construction of the first connecting mechanism;

FIG. 8 is a schematic view of a structure of the movable member;

FIG. 9 is a schematic view of the structure of one end view of the handpiece;

FIG. 10 is a schematic illustration of one configuration of a sensor emitting laser stripe impinging on a pipe to form a laser profile;

FIG. 11 is an illustration of another construction in which a sensor emits a laser stripe that impinges on a pipe to form a laser profile;

FIG. 12 is a schematic view of yet another configuration in which laser stripes from a sensor impinge on a pipe to form a laser profile;

FIG. 13 is a schematic view of a travel mechanism;

FIG. 14 is a schematic view of a brake mechanism;

FIG. 15 is a schematic view of a construction of a compliant wheel assembly;

FIG. 16 is a schematic diagram of a hydraulic system;

FIG. 17 is an overall schematic of another in-line welder of the present invention;

FIG. 18 is a schematic structural diagram of an integrated intelligent pipeline internal welding machine according to an embodiment of the present disclosure;

FIG. 19 is a schematic diagram of a posture adjustment system according to an embodiment of the present disclosure;

fig. 20 is a schematic structural diagram of an attitude adjustment device according to an embodiment of the present application;

FIG. 21 is a flowchart of a method for adjusting the posture of an internal welding machine according to an embodiment of the present disclosure;

FIG. 22 is a schematic structural view of an inner welding machine passing through an elbow provided in an embodiment of the present application;

FIG. 23 is a schematic diagram of a control system according to an embodiment of the present disclosure;

FIG. 24 is a flowchart of an interface method of an internal welding machine according to an embodiment of the present disclosure;

FIG. 25 is a schematic structural view of an internal welding machine according to an embodiment of the present disclosure;

FIG. 26 is a schematic view of a welding unit and a groove in a welding process in an enlarged part in accordance with an embodiment of the present application;

fig. 27 is a schematic diagram of down-sampling groove contour data collected by a sensor according to an embodiment of the present application to convert the groove contour data into a picture;

fig. 28 is a schematic diagram of a result of performing corner detection on a groove profile according to an embodiment of the present application;

fig. 29 is a schematic diagram of a groove contour fitting result provided in an embodiment of the present application.

In the figure:

the machine head 1, the machine body 2, the first connecting mechanism 3, the stationary end 31, the movable end 32, the movable member 33, the inclined slide rail 331, the slider 332, the driving mechanism 333, the actuating rod 334, the tensioning mechanism 11, the front tensioning assembly 111, the rear tensioning assembly 112, the welding mechanism 12, the welding unit 121, the sensor 4, the traveling mechanism 51, the traveling wheel assembly 511, the pushing mechanism 512, the traveling motor 513, the braking mechanism 52, the brake cylinder 521, the brake pad 522, the holding elastic member 523, the flexible wheel assembly 53, the wheel 531, the wheel seat 532, the elastic assembly 533, the angle adjusting motor 534, the rear wheel 54, the battery unit 6, the welding power supply 7, the hydraulic system 8, the front tensioning cylinder 81, the rear tensioning cylinder 82, the traveling cylinder 83, the protective gas cylinder 9, the second connecting mechanism 10, the first end 101, the second end 102, the universal joint 103, and the flexible connecting member 104;

The welding device comprises a first section 201, a welding device 202, a tensioning assembly 203, a posture adjusting device 204, a second section 205, a movable platform 2041, a linear driving mechanism 2042, a fixed platform 2043, a movable end mounting seat 2044 and a fixed end mounting seat 2045;

cone head mechanism 301, multi-degree-of-freedom adjusting mechanism 303, welding unit 304, expansion shoe 305, expansion device 306, machine body mechanism 302, running gear 308, brake 309, flexible front wheel 3010, fixed steel pipe 3011, and bevel area 3012.

Detailed Description

The technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

The embodiment of the invention discloses an in-pipeline welding machine, which effectively improves the bending capacity, improves the passing performance, has good controllability and high precision of gesture adjustment, and can accurately and efficiently carry out pipeline butt joint and welding connection.

Example 1

As shown in fig. 1 and 2, an in-pipeline welding machine mainly comprises a machine head 1, a machine body 2 and a first connecting mechanism 3;

The machine head 1 is provided with a tensioning mechanism 11 and a welding mechanism 12;

the machine body 2 is provided with a traveling system for traveling in the pipeline;

the machine head 1 is connected with the machine body 2 through a first connecting mechanism 3, and the first connecting mechanism 3 has controllable movable freedom degree so as to enable the machine head 1 and the machine body 2 to relatively deflect.

1-3, the tensioning mechanism 11 comprises a front tensioning assembly 111 and a rear tensioning assembly 112 which are axially arranged at intervals along a pipeline, the welding mechanism 12 is arranged between the front tensioning assembly 111 and the rear tensioning assembly 112, the front tensioning assembly 111 and the rear tensioning assembly 112 respectively comprise a plurality of tensioning units distributed along the circumference, the welding mechanism 12 comprises a plurality of welding units 121 distributed along the circumference, the tensioning mechanism 11 and the welding mechanism 12 are coaxial, namely, the distribution circumference of the tensioning units and the distribution circumference of the welding units are coaxial, the welding units 121 are welding executing mechanisms, and are provided with components such as wire reels, wire feeders and welding guns, so that the inner bevel grooves of two pipeline end grooves are welded into a whole;

The machine body 2 of the welding machine in the pipeline walks along the inside of the fixed pipeline through the walking system, the machine head 1 moves along with the machine body 2, and finally the machine head 1 is moved to the position of the welding seam between the two pipelines to be butted, specifically, as shown in fig. 5, the welding gun of each welding unit of the welding mechanism 12 on the machine head 1 is just the center of the welding seam between the end grooves of the two pipelines to be butted (specifically, the welding seam refers to an annular gap between the end grooves of the two pipelines to be butted, which is not yet welded), the front tensioning assembly 111 and the rear tensioning assembly 112 are positioned at two sides of the welding mechanism 12 in the axial direction, the front tensioning assembly 111 and the rear tensioning assembly 112 are respectively positioned in the two pipelines to be butted, and the front tensioning assembly 111 and the rear tensioning assembly 112 are respectively tensioned outwards to prop the inner walls of the pipelines, so that the welding seam between the two pipelines is respectively fixed with the front tensioning assembly 111 and the rear tensioning assembly 112, and the welding mechanism 12 is also kept in a state of being just the center, and the welding seam can be stably and accurately welded.

In this embodiment, as shown in fig. 1, 2 and 6, the first connection mechanism 3 is a controllable movable connection mechanism, and can enable the nose 1 to controllably deflect relative to the machine body 2 according to needs, so that the whole in-pipeline welding machine becomes a curved shape, and thus the over-bending capability of the in-pipeline welding machine can be improved through the curved pipe section of the pipeline, specifically, the first connection mechanism 3 includes a static end 31 and a movable end 32, the static end 31 is connected with the machine body 2, the movable end 32 is connected with the nose 1, a plurality of controllable movable members 33 are arranged in parallel between the static end 31 and the movable end 32 to enable relative movement between the static end 31 and the movable end 32, the first connection mechanism 3 is a multi-degree-of-freedom parallel movement mechanism, preferably, six movable members 33 are arranged in parallel between the static end 31 and the movable end 32, the first connecting mechanism 3 thus constitutes a six-degree-of-freedom parallel motion mechanism having six degrees of freedom of motion, and in terms of a three-dimensional rectangular coordinate system, the first connecting mechanism 3 includes degrees of freedom of motion along the x, y, and z axes, respectively, and also includes degrees of freedom of rotation about the x, y, and z axes, respectively, specifically, when the in-pipe welder is in a pipe, the nose 1 and the body 2 are distributed back and forth along the axial direction of the pipe, so that the stationary end 31 and the moving end 32 of the first connecting mechanism 3 are distributed back and forth along the axial direction of the pipe, the axial direction of the pipe is defined as the z axis direction, the cross-sectional direction of the pipe is defined as the x-y plane direction, and when the body 2 of the in-pipe welder is in the pipe, the body 2 is in a stable state relative to the pipe, the machine head 1 can translate along the axial direction of the pipeline relative to the machine body 2 or translate along the section direction of the pipeline under the action of the first connecting mechanism 3, or rotate around the axial direction of the pipeline or rotate around any radial direction of the section direction of the pipeline, and in general, the machine head 1 can flexibly and accurately move and deflect relative to the machine body 2 under the drive of the first connecting mechanism 3, so that the requirements of bent pipe sections with various bending radiuses can be accurately matched, the pipeline inner welding machine can be integrally bent and deformed to required bending degrees, and the smooth pipe sections can pass through the bent pipe sections.

In this embodiment, the movable member 33 is a linear telescopic member, one end of the linear telescopic member is movably connected with the stationary end 31, the other end of the linear telescopic member is movably connected with the movable end 32, specifically, two ends of the linear telescopic member are respectively connected to the stationary end 31 and the movable end 32 through universal joints, the movable end 32 can be driven to move relative to the stationary end 31 by controlling the telescopic amount of each linear telescopic member, the first connecting mechanism 3 comprises six degrees of freedom of movement, the movable end 32 can translate and deflect relative to the stationary end 31, and the structure is compact, and the control is convenient and precise. The linear telescopic component can specifically adopt an air cylinder, a hydraulic cylinder, an electric cylinder and the like, the electric cylinder is preferably adopted in the embodiment, compared with pneumatic and hydraulic modes, the electric cylinder has the advantages of high transmission efficiency, high speed, high positioning precision, mute operation, simple structure, convenience in maintenance, high reliability and safety, stable operation, long service life and the like, so that the pose of the machine head 1 can be accurately adjusted, the machine head 1 deflects relative to the machine body 2 to enable the whole welding machine in a pipeline to be changed into a bending mode and pass through a bent pipe section, the bending capacity is improved, the machine head 1 can also carry out translational movement along the axis direction of the pipeline, the tensioning mechanism 11 and the welding mechanism 12 on the machine head 1 can be accurately matched with the end parts of the pipeline, and finally the welding mechanism 12 is accurately and exactly aims at the center of a welding seam between two pipeline end parts to be butted, so that the welding quality is improved.

The first connection mechanism 3 in this embodiment specifically adopts a parallel motion mechanism with six degrees of freedom, and the first connection mechanism 3 may also adopt a serial motion mechanism with six degrees of freedom, such as an articulated mechanical arm, for example, three linear motion mechanisms that are sequentially connected in series, and each linear motion mechanism is provided with a rotation mechanism. Compared with a six-degree-of-freedom serial motion mechanism, the six-degree-of-freedom parallel motion mechanism has high rigidity and good structural stability, and because the six-degree-of-freedom parallel motion mechanism has higher rigidity, the six-degree-of-freedom parallel motion mechanism has higher bearing capacity under the condition that the six-degree-of-freedom parallel motion mechanism and the six-degree-of-freedom serial motion mechanism are under the same dead weight or volume, and the output errors of the tail ends of the six-degree-of-freedom serial motion mechanisms are accumulated and amplified, so that the integral motion errors are large and the precision is low, the integral motion errors of the six-degree-of-freedom parallel motion mechanism are not accumulated and amplified, the integral motion errors of the six-degree-of-freedom parallel motion mechanism are averaged, so that the errors are small and the micro-motion precision is high, and the traveling motor and the transmission system of the six-degree-of-freedom serial motion mechanism are mostly placed on a moving joint arm, the inertia of the system is increased, the dynamic performance is deteriorated, the walking motor of the six-degree-of-freedom parallel motion mechanism is usually arranged on the inactive static end, the motion load is reduced, the six-degree-of-freedom parallel motion mechanism adopts a symmetrical structure, each movable member is symmetrically distributed in the circumferential direction, the isotropy is good, the working space of the six-degree-of-freedom parallel motion mechanism is small, the movable adjustment can be carried out in a small space range, the working space of the six-degree-of-freedom serial motion mechanism is large, further, on the position solving, the six-degree-of-freedom serial motion mechanism is easy to solve, but the inverse solution is complex, the six-degree-of-freedom parallel motion mechanism is easy to solve, the position and the gesture of the movable end are solved by taking the six-degree-of-freedom parallel motion mechanism as an example, the inverse solution refers to solving the expansion and contraction amount of the movable member through calculation by knowing the position and the posture of the movable end.

In the prior art, a flexible deflection mechanism is also adopted to be connected between the machine head and the machine body so as to enable the machine head to deflect relative to the machine body to realize overbending, but the flexible deflection mechanism adopted in the prior art is usually a universal joint structure or a structure formed by combining a universal joint and elasticity, and the flexible deflection mechanism realizes passive deflection, namely, only when a welding machine in a pipeline advances to a bent pipe section and the machine head touches the inner wall of the bent pipe section, the flexible deflection mechanism can be enabled to move under the reaction force of the inner wall of the bent pipe section to the machine head, so that the machine head deflects relative to the machine body, and then passes through the bent pipe section in a state that the machine head is deflected relative to the machine body, the machine head always contacts the inner wall of the bent pipe section in the whole process of passing through the bent pipe section, so that the machine head and the inner wall of the pipeline are easily worn, the first connection mechanism 3 in this embodiment realizes active deflection, and the first connection mechanism is controlled to make the movable end 32 perform active deflection movement relative to the static end 31, that is, the nose 1 deflects relative to the machine body 2 along with bending of the pipe, so that the whole in-pipe welding machine is in a bent form to pass through a bent pipe section, preferably, the nose 1 can be actively kept in a state that the central axis of the nose 1 coincides with the central axis of the pipe where the nose 1 is located (the welding units 121 of the welding mechanism 12 are circumferentially distributed on the nose 1, the central axis of the welding mechanism 12 coincides with the central axis of the nose 1, so that when the central axis of the nose 1 coincides with the central axis of the pipe where the nose 1 is located, the central axis of the welding mechanism 12 coincides with the central axis of the pipe where the welding mechanism 12 is located), therefore, the outer circumferences of the tensioning mechanism 11 and the connecting mechanism 12 on the machine head 1 and the inner wall of the pipeline keep uniform intervals in the whole circumferential direction, the machine head can not contact and collide with the inner wall of the bent pipe section in the whole process of passing through the bent pipe section, the smoothness and the safety reliability of the overbending can be better ensured, of course, if the machine head 1 can deflect relative to the machine body 2 and the machine head 1 is not contacted with the inner wall of the pipeline only for realizing the initiative smooth overbending, the central axis of the machine head 1 is not required to completely coincide with the central axis of the pipeline at the position of the machine head 1 during overbending, the central axis of the machine head 1 and the central axis of the pipeline at the position of the machine head 1 can be parallel or have a small included angle, and the interval is not required to be consistent in the whole circumferential direction as long as the machine head 1 and the pipeline are spaced in the whole circumferential direction.

In the case of the in-pipe welding machine of the present embodiment, when the machine head 1 is connected to the machine body 2 through the first connection mechanism 3, a manner of manually controlling the first connection mechanism 3 to perform bending may be adopted, specifically, the movable end 32 is moved relative to the static end 31 by manually controlling each movable member 33 in the first connection mechanism 3, in other words, the first connection mechanism 3 is manually controlled to make the machine head 1 translate or deflect relative to the machine body 2, specifically, a manner of on-site observation, that is, observing the position and posture of the machine head 1 relative to the curved pipe section, then manually controlling the first connection mechanism 3 to make the machine head 1 move relative to the machine body 2 until the distance between the machine head 1 and the inner wall of the curved pipe section is substantially consistent in the whole circumferential direction, that is, the state that the central axis of the machine head 1 deflects relative to the machine body 2 and reaches the central axis of the pipe at the pipe position where the machine head 1 is located, in other words, the in-pipe welding machine is made to perform active adaptive bending deformation according to the curved pipe section, so that the in-pipe welding machine can smoothly pass through the curved pipe section; the method can also be that the deflection gesture required by the machine head 1 relative to the machine body 2 is calculated under the condition that the bending radius of the bending pipe section is known in advance, then the first connecting mechanism 3 is controlled manually or under the control of a system to act, so that the machine head 1 performs accurate deflection movement relative to the machine body 2, and the in-pipeline welding machine performs active adaptive bending deformation according to the bending pipe section, and finally, the in-pipeline welding machine can be ensured to pass through the bending pipe section smoothly.

Example two

As shown in fig. 7 and 8, on the basis of the first embodiment, the first connection mechanism 3 is replaced by another structure, the first connection mechanism 3 includes a stationary end 31 and a movable end 32, the stationary end 31 is connected with the machine body 2, the movable end 32 is connected with the machine head 1, six controllable movable members 33 are arranged in parallel between the stationary end 31 and the movable end 32 so that the stationary end and the movable end can move relatively, specifically, the movable members 33 include an actuating rod 334 and an oblique moving mechanism, the oblique moving mechanism includes an oblique slide 331, a slide 332 and a driving mechanism 333, the slide guiding direction of the oblique slide 331 is fixedly arranged on the stationary end 31, the slide 332 is slidably arranged on the oblique slide 331, the slide 332 is driven by the driving mechanism 333 to slide along the oblique slide 331, the driving mechanism 333 can be specifically a motor driven screw rod pair mechanism, a motor driven rigid body matching structure, a synchronous belt mechanism and the like, the actuating rod 334 is a length-disabled movable end, the actuating rod 334 is provided with a universal joint, the two ends of the actuating rod 334 are connected with the movable end 31 in a certain angle, specifically, the two ends of the oblique slide 331 are distributed in a certain angle range of the same circumference, the oblique slide 31 and the two end are distributed in a certain directions, the same as the oblique slide 31, the two end is distributed in a certain direction, and the same as the oblique slide 31 is in a certain direction, and a certain direction is in a space, and a space is in a space.

The first connecting mechanism 3 is a parallel motion mechanism with six degrees of freedom, the sliding blocks 332 slide along the inclined sliding rail 331 so that the end part with the actuating rod 334 slides along the inclined sliding rail 331 synchronously, the sliding block 332 on the six movable members 33 can be matched with the sliding block 332 along the inclined sliding rail 331 respectively to realize the motion of the movable end 32 with six degrees of freedom in a three-dimensional space, so that the movable end 32 can translate and deflect relative to the stationary end 31, the first connecting mechanism 3 is applied to the welding machine in a pipeline, the nose 1 can deflect controllably relative to the machine body 2, the whole welding machine in the pipeline is changed into a bent form, the bent pipe section of the pipeline can pass through, and the overbending capability of the welding machine in the pipeline is improved.

The first connecting mechanism may be a parallel motion mechanism or a serial motion mechanism, and the first connecting mechanism may have only two controllable degrees of motion, three degrees of motion and the like, for the parallel motion mechanism, various multi-degrees of motion may be realized by designing the number of the movable members connected in parallel between the static end and the movable end, the specific structure of the movable members, and the connection relationship between the movable members and the static end and the movable end, but the specific structures of the movable members in the first embodiment and the second embodiment are different, and six degrees of motion are realized, for example, the movable members may be three in parallel between the static end and the movable end, the movable members specifically adopt linear telescopic members, two ends of the two linear telescopic members are respectively connected to the static end and the movable end through universal joints, and two ends of the third linear telescopic member are respectively hinged to the static end and the movable end. For the tandem movement mechanism, various degrees of freedom of movement can be realized by setting the number of joints, the connection relation of joint members, and the like.

When the first connection mechanism is needed to realize the bending, the first connection mechanism can only comprise two controllable movable degrees of freedom, the two movable degrees of freedom are illustrated by a coordinate system shown in fig. 6, the two movable degrees of freedom can be rotational degrees around an x axis and a y axis respectively, the rotational degrees of freedom can also be rotational degrees around the x axis and the z axis respectively, the two movable degrees of freedom of the first connection mechanism can be realized by adjusting the posture of the machine head respectively around the x axis and the z axis, and in particular, the machine body of the welding machine in the pipeline keeps a posture which does not rotate relative to the pipeline to move along the axis of the pipeline, the first connection mechanism only comprises two controllable movable degrees of freedom can deflect the machine head in any direction so as to bend and turn through the pipeline which bends in any direction, for example, the first connection mechanism can bend and turn around the y axis, when the two movable degrees of freedom of the first connection mechanism are rotational degrees around the x axis respectively around the y axis, the machine head posture can be realized by adjusting the posture of the machine head, and when the two movable degrees of freedom of the first connection mechanism are rotational degrees around the x axis and the z axis respectively (the first connection mechanism is rotated around the first axis, the first rotation axis is turned around the first axis, and then the first rotation axis is enabled to turn around the first axis along the first rotation axis, and the first connection direction is turned around the first axis; when the body of the welding machine in the pipeline can rotate relative to the pipeline, the first connecting mechanism can realize the pipeline which is bent in any direction by at least one rotation degree of freedom (the rotation axis is along the x-y plane).

When the first connecting mechanism is required to realize the alignment, the first connecting mechanism can comprise three controllable movable degrees of freedom, and the three movable degrees of freedom can comprise three movable degrees of freedom in the direction of a z axis and three movable degrees of freedom around the x axis and the y axis respectively, so that the deflection gesture of the machine head relative to the machine body can be adjusted through the movable degrees of freedom around the x axis and the y axis, preferably, the central axis of the welding mechanism on the machine head is overlapped with the central axis of the pipeline to achieve a coaxial state, the machine head can be moved in the axial direction of the end part of the pipeline by the movable degrees of freedom in the direction of the z axis, and the welding mechanism on the machine head can accurately and positively realize the accurate alignment of the welding seam center between two pipelines to be abutted, and further realize the accurate alignment of the bent pipe sections of the pipeline; the three movable degrees of freedom can also comprise a movable degree of freedom in the direction of a z axis and a rotational degree of freedom around the y axis and the z axis respectively, and the accurate alignment can be realized; when the body of the welding machine in the pipeline can rotate relative to the pipeline, the first connecting mechanism can meet the requirement of the contra-opening adjustment by at least only needing the moving freedom degree in the z-axis direction and one rotating freedom degree (the rotating axis is along the x-y plane).

Example III

As shown in fig. 1 and fig. 2, on the basis of the first embodiment or the second embodiment, a sensor 4 for detecting a pipeline is further provided on the machine head 1, a control system receives the collected data detected by the sensor 4 and performs analysis processing to obtain control parameters, the first connection mechanism 3 acts according to the control parameters to adjust the pose of the machine head 1, the sensor 4 is utilized to automatically control the action of the first connection mechanism 3, and the sensor 4 detects the pipeline to obtain the relative pose relationship between the pipeline and the machine head 1, so that the pose of the machine head 1 relative to the machine body 2 is automatically adjusted according to the condition of the pipeline, smooth overbending of a welding machine in the pipeline and accurate contraposition and welding operation are ensured, the degree of automation is improved, and the welding quality is ensured.

In this embodiment, a plurality of sensors 4 are circumferentially spaced on the handpiece 1, as shown in fig. 9, the sensors 4 are specifically provided with three sensors, and the sensors 4 are uniformly spaced along the circumferential direction, and the central axis of the circumference where the sensors 4 are located coincides with the central axis of the tensioning mechanism 11, that is, the central axis of the circumference where the sensors 4 are located coincides with the central axis of the welding mechanism 12. The pipelines are detected at a plurality of positions in the circumferential direction through the sensors 4, and analysis processing is carried out on the data detected and collected by the sensors 4, so that the pose of the machine head 1 is controlled and adjusted more accurately. Firstly, the sensor 4 can be used to detect whether the central axis of the machine head 1 is located in the welding mechanism 12 and the central axis of the pipeline where the welding mechanism 12 is located is coincident (specifically, the pipeline comprises a straight pipe section and a curved pipe section, the central axis of the straight pipe section is in a straight line shape, the central axis of the welding mechanism 12 is completely coincident when the welding mechanism 12 is located in the straight pipe section, the central axis of the curved pipe section is in a curved shape, the central axis of the welding mechanism 12 is actually completely coincident with the tangential direction of the central axis of the pipeline where the welding mechanism 12 is located when the welding mechanism 12 is located in the curved pipe section, which can be simply called that the central axis of the welding mechanism 12 is coincident with the central axis of the pipeline), since the central axis of the circumference where the sensor 4 is located is coincident with the central axis of the welding mechanism 12, which can be in a ranging mode, when the distances from the three sensors 4 to the inner wall of the pipeline are equal, it can be judged that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline at the position of the pipeline where the welding mechanism 12 is located at the moment, so that the machine head 1 with the tensioning mechanism 11 is positioned at the very center of the section of the pipeline, the position of the machine head 1 is detected in real time by the sensor 4 and regulated in real time by the first connecting mechanism 3 in the whole process of the running of the welding machine in the pipeline, so that the state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline is maintained, the welding machine in the pipeline smoothly runs along the pipeline, when the tensioning mechanism 11 on the machine head 1 does not expand outwards in the radial direction, the outer diameter size of the whole machine head 1 is smaller than the inner diameter of the pipeline, the machine head 1 is always kept at the very center of the pipeline in the running process of the welding machine head 1, the machine head 1 cannot contact with the inner wall of the pipeline in the running process, ensuring the smoothness of the passage; when the pipeline internal welding machine passes through a bent pipe section of the pipeline, the central axis of the pipeline is bent, the central axis of the welding mechanism 12 is kept to coincide with the central axis of the pipeline at the position of the pipeline where the welding mechanism 12 is positioned through the detection of the sensor 4 and the automatic adjustment of the first connecting mechanism 3, namely, the machine head 1 is deflected relative to the machine body 2, so that the whole pipeline internal welding machine is bent and deformed, and can smoothly pass through the bent pipe section, the machine head 1 is kept in a state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline in the whole process of passing through the bent pipe section, the machine head 1 is not in collision contact with the inner wall of the bent pipe section, and the smoothness of overbending is ensured; the sensor 4 can also be used for automatic alignment, the alignment refers to accurately facing the welding mechanism 12 on the machine head 1 to the center of a welding seam between two pipeline end grooves to be abutted, specifically, the sensor 4 is used for detecting the position of the pipeline end, then the running system is controlled to stop the welding machine in the pipeline at a required position so that the welding mechanism 1 on the machine head 1 of the welding machine in the pipeline can be aligned to the welding seam, the running system has relatively low action precision, the welding mechanism 12 is difficult to accurately face the center of the welding seam between two pipelines, therefore, the running system and the first connecting mechanism 3 can be used for cooperation, namely, the running system stops the welding machine in the pipeline at a coarse precision position, at this moment, the welding mechanism 12 on the machine head 1 is positioned in a region adjacent to the welding seam between the two pipelines, then the first connecting mechanism 3 is used for driving the machine head 1 to move for fine adjustment, finally, the welding gun of each welding unit of the welding mechanism 12 does not need to accurately face the center between the two pipeline end grooves to be abutted, namely, the welding mechanism 12 has high automation degree, high alignment precision and high efficiency, and high welding quality can be connected.

Specifically, the sensor 4 in this embodiment is a stripe laser displacement sensor, laser stripes emitted by the sensor 4 are irradiated on a pipeline, so that a laser contour line is formed on the pipeline, the sensor 4 detects that an acquired laser contour line image is pipeline contour data, the pipeline contour data is sent to a control system for analysis processing, so that the pose of the current machine head 1 relative to the pipeline can be obtained, then the control system analyzes and processes the acquired control parameters and sends the control parameters to the first connection mechanism 3, and the first connection mechanism 3 correspondingly adjusts the machine head 1 relative to the pipeline according to the control parameters to achieve a required accurate pose;

more specifically, the control system includes a coaxial unit, the coaxial unit is used for analyzing the acquired data detected by the processing sensor 4 to obtain control parameters for coaxial, the first connection mechanism 3 acts according to the control parameters for coaxial (specifically, each movable member 33 in the first connection mechanism 3 acts correspondingly to deflect and/or translate the movable end 32 relative to the static end 31), so that the central axis of the welding mechanism 12 on the machine head 1 coincides with the central axis of the pipeline at the position of the welding mechanism 12, and the coaxial unit is used for keeping the machine head 1 in a state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline when the welding machine in the pipeline moves along the pipeline, so that when the pipeline is bent, the first connection mechanism 3 automatically drives the machine head 1 to deflect relative to the machine body 2 to adapt to bending of the pipeline, the whole welding machine in the pipeline becomes a bent state, and the welding machine in the pipeline keeps the state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline smoothly passes through the bent pipe section of the pipeline, thereby realizing automatic coaxial overbending.

Specifically, the running system on the machine body 2 drives the machine body 2 to run along the pipe towards the side where the machine head 1 is located, the position of the sensor 4 on the machine head 1 is located at the front side of the running direction relative to the tensioning mechanism 11 and the welding mechanism 12, in other words, the sensor 4 is far away from the machine body 2 relative to the tensioning mechanism 11 and the welding mechanism 12, the emitting direction of the laser stripe of the sensor 4 faces to the tensioning mechanism 11 and the side where the welding mechanism 12 is located, the emitting direction of the laser stripe of the sensor 4 is inclined to the axial direction of the tensioning mechanism 11 and faces to the radial outer side of the tensioning mechanism 11, the length direction of the laser stripe of the sensor 4 is located in a plane passing through the central axis of the tensioning mechanism 11, further, the stripe irradiation area of the laser stripe of the sensor 4 covers the radial outer side area opposite to the welding mechanism 12, so that the pose of the machine head 1 can be detected in real time and accurately adjusted to enable the welding mechanism 12 to accurately face to the center of a welding seam between two pipes.

When the positions of the machine head 1 relative to the pipeline are different, the laser stripes emitted by the sensor 4 form different forms of laser contour lines when the laser stripes emitted by the sensor 4 are irradiated on the pipeline. Specifically, when the deflection state of the central axis of the welding mechanism 12 on the machine head 1 relative to the central axis of the pipe is different, for example, when the machine head 1 is in a straight line pipe section of the pipe, description is made, when the central axis of the welding mechanism 12 is completely coincident with the central axis of the pipe, the laser contour line formed by the laser stripe emitted by the sensor 4 irradiates on the inner wall of the pipe to form a straight line as shown in a shadow area on the inner wall of the pipe in fig. 10, and when the central axis of the welding mechanism 12 and the central axis of the pipe have a deviation included angle, the length direction of the laser stripe emitted by the sensor 4 is inclined to the axial direction of the pipe, so that the laser contour line formed by the laser stripe emitted by the sensor 4 forms a spiral line as shown in the shadow area in fig. 11 on the inner wall of the pipe, thereby the deviation state of the central axis of the welding mechanism 12 relative to the central axis of the pipe can be judged by analyzing and processing the laser contour line images, the laser contour line image collected by the sensor 4 in real time can be specifically, the laser contour line image and the contour image (the contour image formed by the laser contour line irradiated on the inner wall of the pipe when the central axis of the welding mechanism 12 is completely coincident with the central axis of the pipe in fig. 10) can be automatically controlled to form a standard curve with the central axis of the pipe in order to smoothly run along the central axis of the pipe 1 of the pipe by automatically controlling a coaxial bending mechanism to be matched state, so that the coaxial welding mechanism can smoothly run along the coaxial line 1 can be realized.

The cooperation of the first connecting mechanism 3 and the sensor 4 is used for realizing automatic coaxial overbending and automatic accurate alignment, wherein the alignment refers to the adjustment of the pose of the machine head 1 so that the welding mechanism 12 on the machine head 1 is opposite to the center of a welding seam between two pipeline end grooves to be abutted. The control system comprises a butt joint unit, the butt joint unit analyzes and processes the acquired data detected by the sensor 4 to obtain control parameters for butt joint, and the first connecting mechanism 3 acts according to the control parameters for butt joint so that the welding mechanism 12 is opposite to the center of a welding seam between two pipelines to be butted. The first connecting mechanism 3 is a multi-degree-of-freedom moving mechanism, and specifically may be a parallel moving mechanism or a serial moving mechanism, the first connecting mechanism 3 may have two degrees of freedom to six degrees of freedom, the number of specific dimensions of the degrees of freedom may satisfy the butt adjustment, the first connecting mechanism 3 has a certain adjustment movement range, as long as the error between the current position and the optimal accurate position of the welding mechanism 12 on the machine head 1 is less than or equal to the adjustment movement range of the first connecting mechanism 3, the welding mechanism 12 can be directly opposite to the center of the welding seam between two pipes to be butted through the adjustment action of the first connecting mechanism 3, that is, the accurate butt adjustment is achieved.

Specifically, with reference to fig. 10 and fig. 12, when the positions of the head 1 relative to the end of the pipeline are different, laser contour lines with different shapes are formed, and the head 1 of the welding machine in the pipeline is kept in a state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline, and the head 1 of the welding machine in the pipeline walks along the pipeline, when the head 1 is completely positioned in the pipeline of the straight pipeline section or the tensioning mechanism 11 and the welding mechanism 12 are completely positioned in the pipeline of the straight pipeline section, the laser stripes emitted by the sensor 4 only irradiate on the inner wall of the pipeline, so that the formed laser contour lines are in a straight line as shown in a shadow area in fig. 10, and when the welding machine in the pipeline continues to travel until the laser stripes emitted by the sensor 4 irradiate on a groove at the end of the pipeline, the formed laser contour lines are approximately in an L shape as shown in the shadow area in fig. 12, so that the position of the head 1 of the welding machine in the pipeline relative to the pipeline port can be judged by analyzing and processing the images of the laser contour lines, the head 1 of the welding machine in the pipeline can be in real time, the laser contour line image acquired by the sensor 4 and the preset contour image (the preset contour image can be in the state that the shadow area 12 is in the shadow area in the pipeline section) can be automatically matched with the central axis of the pipeline 1, namely, the central axis 1 is automatically controlled to automatically, and the position of the end of the pipeline is automatically adjusted, and the joint position of the head 1 is automatically adjusted, and the end of the pipeline is automatically, and the end is welded to the end of the pipeline is in a position of the pipeline to the pipeline, and the end is automatically in a position of the end position of the pipeline, and the end is automatically in a position of a joint line, and a position line.

The docking unit includes:

a scene judging module for analyzing and processing the data acquired by the sensor 4 to judge whether the sensor 4 detects the butt scene of the end part of the pipeline, when the pipeline welder moves along the pipeline through the walking system, the laser stripes emitted by the sensor 4 irradiate on the pipeline to form laser contour lines, when the positions of the head 1 of the pipeline welder relative to the end part of the pipeline are different, the laser contour lines formed by the sensor 4 on the head 1 are in different forms, specifically, the laser contour lines formed when the laser stripes emitted by the sensor 4 irradiate on the inner wall of the pipeline are in different forms with the laser contour lines formed when the laser stripes emitted by the sensor 4 irradiate on the end part of the pipeline, the position of the head 1 relative to the end part of the pipeline can be analyzed and judged by analyzing and processing the laser contour line images detected by the sensor 4, when the laser stripe irradiates the inner wall of the pipeline, the welding mechanism 12 on the machine head 1 is far away from the end of the pipeline, the welding mechanism is not in the butt-joint scene but in the locating traveling scene, the welding machine in the pipeline continues to travel along the pipeline through the traveling system, when the laser stripe emitted by the sensor 4 irradiates the end of the pipeline, the welding mechanism 12 on the machine head 1 is close to the end of the pipeline, the welding mechanism is in the butt-joint scene, the automatic butt-joint is started, specifically, the sensor 4 detects that the acquired pipeline contour image is acquired, the scene judging module compares the acquired pipeline contour image detected by the sensor 4 with the preset image to judge whether the sensor 4 detects that the end of the pipeline is acquired, the preset image is a standard contour image which is acquired by the sensor 4 and contains the end part of the pipeline under the state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline, so that when the sensor 4 detects that the acquired pipeline contour image is matched with the preset image in real time, the machine head 1 is in a coaxial posture of the central axis of the welding mechanism 12 coinciding with the central axis of the pipeline, in other words, when entering an opposite scene, the machine head 1 is in the coaxial posture of the central axis of the welding mechanism 12 coinciding with the central axis of the pipeline, the efficiency and the precision of subsequent opposite adjustment are facilitated, and in the process that the welding machine in the pipeline is driven by the travelling system to travel along the pipeline, the coaxial unit is always in a working state so as to keep the machine head 1 in the coaxial posture of the central axis of the welding mechanism 12 coinciding with the central axis of the pipeline, thereby ensuring that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline when entering the opposite scene;

The metering module is used for analyzing and processing data acquired by the sensor 4 to obtain the distance from the sensor 4 to a plane where the end of the pipeline is located when the metering module is in a butt-joint scene, the sensor 4 acquires laser contour line images, wherein the laser contour line images contain various data information, the relative position information between the end of the current pipeline and the sensor 4 can be obtained through analyzing and processing the laser contour line images, the welding mechanism 12 on the machine head 1 has an exact and fixed position relation relative to the sensor 4, namely the current relative position information between the end of the pipeline and the welding mechanism 12 is obtained, and the position of the machine head 1 is adjusted conveniently through the first connecting mechanism 3, so that the welding mechanism 12 is right opposite to the center of a welding seam between end grooves of two pipelines to be butted;

the parking module sends out an instruction for controlling the parking machine body 2 of the running system when the distance from the sensor 4 to the plane where the end part of the pipeline is located reaches a running stop condition, specifically the parking module sends out the instruction when the distance from the sensor 4 to the plane where the end part of the pipeline is located reaches a distance range, the running precision of the running system is lower, the welding machine body 2 is difficult to realize that the welding mechanism 12 is opposite to the center of a welding seam between end grooves of two pipelines to be butted only by controlling the running system, therefore, the running system is adopted to stop the welding machine in the pipeline at a rough precision position firstly, at the moment, the welding mechanism 12 is positioned in the vicinity of the welding seam between the end grooves of the two pipelines to be butted, and then the position of the machine head 1 is accurately adjusted by the first connecting mechanism 3, so that the welding mechanism 12 can accurately opposite to the center of the welding seam between the end grooves of the two pipelines to be butted, and more specifically, the sensor 4 is circumferentially arranged on the machine head 1, and the distance from the at least two sensors 4 to the plane where the end parts of the pipelines are located reaches the running stop condition or the running condition when the distance from the sensor 4 to the end part of the pipeline reaches the running stop condition of the pipeline reaches the parking system, and the running stop condition is reached to the running system;

The alignment fine adjustment module analyzes and processes the acquired data detected by the sensor 4 in the stopped state of the machine body 2 to obtain control parameters for fine adjustment (the control parameters for alignment comprise an instruction for controlling the running system to stop the machine body 2 and the control parameters for fine adjustment), the first connection mechanism 3 acts according to the control parameters for fine adjustment in the state that the running system stops the machine body 2 in the pipeline (specifically, each movable member 33 in the first connection mechanism 3 acts correspondingly to enable the movable end 32 to deflect and/or translate relative to the static end 31), when the distance from the sensor 4 to the plane of the end of the pipeline reaches the preset alignment distance, the first connection mechanism 3 stops acting, at the moment, the welding mechanism 12 exactly faces the center of a weld joint between two pipelines to be abutted, and at the moment, the central axis of the welding mechanism 12 coincides with the central axis of a groove at the end of the pipeline, the tightening mechanism 11 expands radially outwards to support and fasten the pipeline, and then the welding mechanism 12 can perform welding operation.

According to the method for aligning the welding machine in the pipeline, the running system drives the welding machine in the pipeline to integrally run in the pipeline, so that when the machine head 1 of the welding machine in the pipeline moves from the inside of the pipeline to the outside of the end part of the pipeline, the control system analyzes and processes collected data detected by the sensor 4 to judge whether the sensor 4 detects the end part of the pipeline or not, namely, whether the welding machine in the pipeline moves to an aligning scene or not is judged, the sensor 4 detects and collects laser contour lines related to the pipeline, the control system analyzes and processes the laser contour lines, specifically, the sensor 4 detects and compares the collected pipeline contour images with preset images to judge whether the sensor 4 detects and collects the end part of the pipeline, for example, when the laser contour lines are in a straight line as shown in fig. 10, laser stripes emitted by the sensor 4 only irradiate on the inner wall of the pipeline, at the moment, the tension mechanism 11 and the welding mechanism 12 on the machine head 1 are far away from the end part of the pipeline, the welding machine in other words, the welding machine in the pipeline is continuously operated normally, and drives the welding machine in the pipeline to integrally run along the pipeline, and when the laser contour lines are in an L shape as shown in fig. 12, the laser contour lines represent that the laser stripes are in L shape, the end part of the pipeline is detected and the end part of the pipeline has been detected by the welding machine in the pipeline, and the laser stripes is irradiated to the end part of the pipeline, and the welding machine in the pipeline is detected;

When the system is in an opposite scene, the control system analyzes and processes the acquired pipeline profile data (laser profile line images) detected by the sensor 4 to obtain the distance from the sensor 4 to the plane of the end part of the pipeline, so as to control the position of the parking machine body 2 of the running system through the distance from the sensor 4 to the plane of the end part of the pipeline;

the running system continues to work normally to drive the welding machine in the pipeline to run wholly along the pipeline, the nose 1 moves further towards the outside of the end of the pipeline, the distance from the sensor 4 to the plane of the end of the pipeline continues to increase, when the distance from the sensor 4 to the plane of the end of the pipeline reaches a running stop condition (the running stop condition can be a specific preset distance value, the preset distance value can be set according to specific conditions), the running system stops the machine body 2, namely the machine body 2 of the welding machine in the pipeline is stopped in the pipeline, at the moment, the welding mechanism 12 on the nose 1 is positioned in the area range adjacent to the welding seam between two pipelines, specifically the running system stops the machine body 2 when the distance from the sensor 4 to the plane of the end of the pipeline exceeds a preset distance value, preferably, the running stop condition is set so that the welding mechanism 12 is still positioned at the inner side of the end of the pipeline when the running system stops the machine body 2, and the nose 1 needs to move towards the outside of the end of the pipeline under the adjusting action of the first connecting mechanism 3 so that the welding mechanism 12 is opposite to the center of the welding mechanism to be abutted against the welding seam;

In the state that the travelling system is stopped at the machine body 2, the control system analyzes and processes the acquired laser contour line image detected by the sensor 4 at the moment to obtain control parameters, the first connecting mechanism 3 acts to drive the machine head 1 to finely adjust according to the control parameters, when the distance from the sensor 4 to the plane of the pipe end reaches the preset alignment distance, the first connecting mechanism 3 stops acting (the automatic alignment is realized by accurately controlling the distance from the sensor 4 to the plane of the pipe end, the distance between the welding mechanism 12 and the sensor 4 in the axis direction of the tensioning mechanism 11 is clear and fixed, therefore, the preset alignment distance is actually equal to the distance between the welding mechanism 12 and the sensor 4 in the axis direction of the tensioning mechanism 11 plus one half of the gap between the two pipe end grooves, when the distance from the sensor 4 to the plane of the pipe end reaches the preset alignment distance, the center of the welding seam between the two pipe end grooves of each welding unit of the welding mechanism 12 can be determined at the moment, the automatic alignment is realized, the distance between the two welding guns 4 is uniformly arranged along the circumference of the preset alignment distance, and the welding distance between the two pipe end grooves reaches the preset center plane, and the automatic alignment is completed.

In the automatic alignment process, the state that the central axis of the welding mechanism 12 on the machine head 1 coincides with the central axis of the pipeline is kept, namely, the control system always analyzes the acquired data detected by the processing sensor 4 to obtain control parameters for coaxial when the running system drives the pipeline inner welding machine to move in the pipeline, the first connecting mechanism 3 acts according to the control parameters for coaxial to maintain the machine head 1 in the state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline, the state that the central axis of the welding mechanism 12 coincides with the central axis of the pipeline is also kept when the running system stops the machine body 2 and the first connecting mechanism 3 drives the machine head 1 to carry out fine adjustment, and the state that the central axis of the welding mechanism 12 coincides with the central axis of a groove at the end part of the pipeline is also needed to be achieved after the automatic alignment is finished, so that the tensioning mechanism 11 can uniformly and stably expand to the radial outside to tension and fix the pipeline, and further ensure that the welding seam between two pipelines to be butted accurately by the welding mechanism 12.

Besides the specific sensor structure, other sensor structures can be adopted, for example, the stripe type laser displacement sensor is changed into a distance sensor, a vision system and the like, the sensor can also be arranged on other positions or other distribution modes, for example, the sensor is arranged on the machine body 2, for example, a circular track is arranged on the machine head 1, the central axis of the circular track coincides with the central axis of the welding mechanism 12, the sensor is arranged on the circular track to move along the circular track, and the sensor can stop and detect the pipeline at any position of the circular track, so that the data at any position of the whole circumference of the pipeline can be detected, the detection can be more accurate, and the flexibility and the applicability are better.

Example IV

As shown in fig. 1, fig. 2 and fig. 13, on the basis of the first embodiment, the running system on the machine body 2 specifically includes a running mechanism 51, the running mechanism 51 includes a plurality of running wheel assemblies 511 that are disposed along the circumferential direction of the machine body 2 at intervals, the running wheel assemblies 511 are connected to a tightening mechanism 512 that is disposed on the machine body 2, the running wheel assemblies 511 are driving wheel mechanisms for driving the machine body 2 to run along the inside of the pipeline, the tightening mechanism 512 is used for pressing the running wheel assemblies 511 on the inner wall of the pipeline, so that sufficient friction force exists between the running wheel assemblies 511 and the inner wall of the pipeline, and thus the situation that slipping and sliding occur during running of the running wheel assemblies 511 is avoided, the climbing capability of a welding machine in the pipeline can be improved, and the running wheel assemblies are applicable to inclined pipe sections with large gradients.

Specifically, the two walking wheel assemblies 511 are arranged on two sides of the machine body 2 in the diameter direction, the tightening mechanisms 512 are tightening hydraulic cylinders connected between the walking wheel assemblies 511 on two sides, the tightening hydraulic cylinders are connected to the machine body 2, the telescopic action of the tightening hydraulic cylinders drives the walking wheel assemblies 511 to move along the diameter direction of the machine body 2, and then the walking wheel assemblies 511 are pressed on the inner wall of a pipeline, the structure is simple and compact, the tightening hydraulic cylinders provide tightening force by adopting hydraulic pressure, the tightening force can be improved under the condition that the volume is not increased, so that slipping and sliding of the walking wheel assemblies 511 are better avoided when the walking wheel assemblies 511 operate, climbing capacity is improved, and safety and reliability of a welding machine in a pipeline in the pipeline in advancing are improved;

Further, each traveling wheel assembly 511 is respectively provided with a traveling motor 513, the traveling motor 513 adopts a motor with a band-type brake, compared with the traditional pneumatic motor, the strength is larger, the self-locking can be completed through the band-type brake, the wheels of the traveling wheel assembly 511 can not rotate when the band-type brake of the traveling motor 513 is self-locked, one layer of guarantee is provided for the braking of the welding machine in the pipeline to stop at the inclined pipe section of the pipeline, because each traveling wheel assembly 511 is provided with an independent traveling motor 513, the traveling wheel assemblies 511 on two sides can work relatively independently, in other words, the traveling speeds of the traveling wheel assemblies 511 on two sides can be different, so that differential overbending can be realized when the traveling wheel assemblies pass through the bent pipe section of the pipeline, specifically, the traveling speed of the traveling wheel assemblies 511 on two sides can be controlled in an electronic differential control mode when the traveling wheel assemblies overbending is overbent, the radius of the inner bending side and the outer bending side is different, and the rotating speed of the traveling wheel assemblies 511 on the outer bending side is required to be higher than the rotating speed of the traveling wheel assemblies 511 on the inner bending side when the smooth overbending is required to be completed;

specifically, when the welding machine in the pipeline is in overbending, if the control parameters of the two travelling motors are consistent, the rotation speed of the travelling wheel assembly at the outer bending side is consistent with that of the travelling wheel assembly at the inner bending side, the speed control mode requires constant speed when the motor is driven into the speed control mode, if the speeds of the two motors are constant at the moment, the resistance of the wheels of the travelling wheel assembly at the outer bending side and the wheels of the travelling wheel assembly at the inner bending side are different, the motor speeds are required to be kept unchanged, the difference is generated between the driving forces provided by the driving devices of the travelling motor at the outer bending side and the travelling motor at the inner bending side, the small difference can be read through the respective driving devices of the two travelling motors, and the moment difference is used as an input feedback quantity, so that the running speeds of the travelling wheel assembly at the outer bending side and the travelling wheel assembly at the inner bending side can be adjusted in real time through PID (proportion integration differentiation) to realize the smooth overbending of the inner wheel, and smooth running of the equipment is not ensured, and the welding machine in the pipeline is easy to be clamped at the position of the bending pipe section by the inner and the outer bending side, so that the welding machine is easy to overcome the damage to the pipe section by the large walking force is required to be caused by forced bending of the welding machine.

Further, as shown in fig. 1, 2 and 14, the running system further includes a brake mechanism 52, where the brake mechanism 52 specifically includes a brake cylinder 521, a brake pad 522 and a retaining elastic member 523, where the brake cylinder 521 is connected to the machine body 2, where the brake pad 522 is driven by the brake cylinder 521 to switch between a braking position and a releasing position, where the brake pad 522 is pressed against an inner wall of a pipeline by the brake cylinder 521 when the brake pad 522 is in the braking position to realize reliable braking, ensure that a welder in the pipeline stably stops in the pipeline, i.e., an inclined pipe section in a roller way does not slip, improve safety and reliability, where the brake pad 522 is separated from the inner wall of the pipeline when the brake pad 522 is in the releasing position, at this time, the welding machine in the pipeline reliably moves along the interior of the pipeline under the driving of the moving mechanism 51, the brake pad 522 is also connected with a holding elastic piece 523 for driving the brake pad 522 to be held at a brake position, even if the brake cylinder 521 is damaged and does not work, the brake pad 522 can still be held at a state of being propped against the brake position in the pipeline under the action of the holding elastic piece 523, the situation of sliding is avoided, the brake situation can be canceled only when the brake cylinder 521 is normal and the brake cylinder 521 actively withdraws the brake pad 522 to a release position, the holding elastic piece 523 is a gas spring, the speed is relatively slow, the dynamic force is not changed greatly, the control is easy, the nearly linear elastic curve is provided, the compression acting force applied to the brake pad is more stable, and the brake stability is ensured.

Further, as shown in fig. 1 and 15, the traveling system includes a flexible wheel assembly 53, the flexible wheel assembly 53 is disposed near the front portion of the machine body 2, the front portion of the machine body 2 is near one side of the machine head 1, the traveling wheel assembly 511 is disposed in the middle of the machine body 2, and the rear portion of the machine body 2 is further provided with a rear wheel 54, the flexible wheel assembly 53 and the rear wheel 54 are driven wheels, and the machine body 2 is supported on the inner wall of the pipeline through the flexible wheel assembly 53, the traveling wheel assembly 511 and the rear wheel 54, so that the machine body 2 can reliably travel along the interior of the pipeline;

the flexible wheel assembly 53 specifically comprises a wheel 531, a wheel seat 532 and an elastic assembly 533, wherein the wheel 531 is arranged on the wheel seat 532, the wheel seat 532 is hinged on the machine body 2, the rotation plane of the wheel seat 532 is along the radial direction of the machine body 2, the elastic assembly 533 is connected between the wheel seat 532 and the machine body 2, the elastic assembly 533 specifically adopts a flexible spring piece, the wheel 531 in the flexible wheel assembly 53 can buffer and stretch in the radial direction of the machine body 2 relative to the machine body 2 through the wheel seat 532 hinged with the machine body 2, and when the welding machine in a pipeline is subjected to external force, for example, a tensioning mechanism works against the inner wall of the pipeline or the machine head 1 contacts and collides with the inner wall of the pipeline, the wheel 531 can deflect relative to the machine body 2 along with the wheel seat 532 so as to enable the elastic assembly to elastically deform, and the elastic assembly is utilized to buffer and absorb the impact force, so that the welding machine in the pipeline can be prevented from being damaged due to impact, and the welding machine in the pipeline can be effectively protected;

And, the flexible wheel assembly 53 further includes an angle adjustment motor 534 disposed on the wheel seat 532 and connected to the wheel 531, where the angle adjustment motor 534 turns to adjust the traveling direction of the wheel 531, the posture of the in-pipeline welding machine is difficult to be guaranteed to be constant in the process of traveling along the inner wall of the pipeline, and the integral in-pipeline welding machine inevitably rotates relative to the pipeline, for example, when the in-pipeline welding machine travels in a horizontal pipeline, the in-pipeline welding machine rotates clockwise to the left, the wheel 531 is turned by the angle adjustment motor 534, so that the wheel 531 rotates to a certain angle to guide the in-pipeline welding machine to rotate anticlockwise to return to a normal posture, a gyroscope can be disposed on the machine body 2 of the in-pipeline welding machine, the posture of the machine body 2 is monitored according to the information of the gyroscope, and the angle adjustment motor 534 is controlled to drive the wheel 531 to turn to adjust and control the posture of the in-pipeline welding machine.

Example five

As shown in fig. 1, on the basis of the fourth embodiment, the welding machine in the pipeline further includes a battery unit 6 integrated on the machine body 2, the battery unit 6 supplies power to the tensioning mechanism 11, the welding mechanism 12, the running system, the first connecting mechanism 3 and the like, the distribution management system of the electric energy is efficient and energy-saving, the distributed electric energy is reasonably managed and distributed, the battery unit 6 adopts a lithium battery, the battery management is performed by the moving BMS system, the safety performance is improved, the battery unit 6 is also provided with a heating component, the battery unit 6 is heated in a low-temperature state, and the operation safety and reliability of the battery unit 6 are improved. The quick charging is utilized, so that the charging is completed within 1.5 hours, and the site construction is greatly facilitated.

The pipeline internal welding machine further comprises a welding power supply 7 integrated on the machine body 2, a delivery rod of the traditional internal welding machine is omitted, and site construction is greatly facilitated. The welding power supply 7 is integrally comprised of a plurality of conventional welding power supplies having three or four positive electrode bond wires and 1 negative electrode bond wire, powered by the in-line welder's own battery unit 6, and the welding power supply 7 is electrically connected to the welding unit of the welding mechanism 12 via the bond wires.

Further, the machine body 2 is further integrally provided with a hydraulic system 8, the hydraulic system 8 provides hydraulic power for a tensioning mechanism 11, a brake mechanism 52 and a pushing mechanism 512 of the travelling mechanism 51, as shown in fig. 16, the hydraulic system 8 comprises a front tensioning cylinder 81, a rear tensioning cylinder 82, a travelling cylinder 83 and a brake cylinder 521 which are arranged in parallel, the front tensioning cylinder 81 corresponds to a front tensioning assembly 111 of the tensioning mechanism 11, the rear tensioning cylinder 82 corresponds to a rear tensioning assembly 112 of the tensioning mechanism 11 so as to realize tensioning and fixing a pipeline, the travelling cylinder 83 corresponds to the pushing mechanism 512 of the travelling mechanism 51 so that the travelling wheel assembly 511 can be tightly abutted against the inner wall of the pipeline, stability is ensured, and the action states of the front tensioning cylinder, the rear tensioning cylinder, the travelling cylinder and the brake cylinder are respectively connected with reversing valves, so that the functions of the assemblies can be realized by flexibly controlling the action states of the hydraulic system 8; the machine body 2 is also integrated with a protective gas cylinder 9, and the protective gas cylinder 9 provides protective gas for a welding mechanism 12 so as to ensure welding quality. ,

Example six

As shown in fig. 17, on the basis of the fifth embodiment, the machine body 2 may be divided into a plurality of sections along the axis direction of the pipe, and adjacent sections are connected by a second connection mechanism 10, where the second connection mechanism 10 is a deflectable connection mechanism, and the second connection mechanism 10 may specifically also adopt the same structure as the first connection mechanism 3 described in the first embodiment, that is, the second connection mechanism 10 may be an active connection mechanism capable of being actively controlled, but compared with the machine head 1 having the tensioning mechanism 11 and the welding mechanism 12, the high precision of the gesture control of the sections of the machine body 2 needs to be relatively low, and only the sections of the machine body 2 need to be relatively deflected to improve the bending performance, so that the second connection mechanism 10 may adopt a passive active connection mechanism.

Specifically, the machine body 2 in this embodiment only includes two sections, the second connection mechanism 10 between the two sections includes a first end 101, a second end 102, a universal joint 103, and a flexible connection member 104, the universal joint 103 and the flexible connection member 104 are connected between the first end 101 and the second end 102, the flexible connection member 104 is distributed in a plurality of circumferential directions of the universal joint 103, the first end 101 is connected with the previous section, and the second end 102 is connected with the next section. The second connecting mechanism 10 has a simple structure and is easy to implement, the second connecting mechanism can passively deflect, active adjustment is not needed, when the pipeline inner welding machine passes through the bent pipe section, each section of the machine body 2 is respectively contacted with the inner wall of the pipeline, under the action of the abutting force of the inner wall of the pipeline on each section, the adjacent sections deflect relatively to match the bending radius of the bent pipe section through the second connecting mechanism, each section of the machine body 2 is changed from original linear arrangement shape to bending arrangement shape, the bending shape of the machine body 2 at the moment is matched with the bending radius of the bent pipe section, and therefore the pipeline inner welding machine can smoothly pass through the bent pipe section, and the bending capacity of the pipeline inner welding machine is further improved.

Furthermore, the machine body 2 is divided into two sections, the modules with different functions can be integrated on the same section according to similar categories, a traveling system and a battery unit are mainly arranged on the section close to the machine head 1, and specifically, a traveling mechanism 51, a braking mechanism 52, a flexible wheel assembly 53, a rear wheel 54 and other assemblies are arranged on the section close to the machine head 1; the section far away from the machine head 1 is mainly an energy section, and the section far away from the machine head 1 is mainly provided with a protective gas cylinder 9, a welding power supply 7, a hydraulic oil tank and the like.

Posture adjusting system of internal welding machine

The embodiment of the application provides a posture adjustment system of an internal welding machine, which comprises a posture adjustment device 204, an electrical control module and a sensor 4, wherein the posture adjustment device 204 is arranged between a first section 201 and a second section 205 of the internal welding machine. The electrical control module can control the posture adjusting device 204 to adjust the posture of the internal welding machine according to the data acquired by the sensor 4. Specifically, the posture adjusting device 204 may be disposed between any two sections of the internal welding machine, and each section may be a rigid non-rotatable member, or may be an additional hinge structure designed in the section. As a preferred embodiment of the present application, as shown in fig. 18, the first section 201 is a bit mechanism on which an electric element, a tension assembly 203, and a welding mechanism are provided; the second section 205 is a body mechanism provided with a running gear, a braking device, a driving device, etc.

The posture adjusting device 204 includes a moving platform 2041, a fixed platform 2043, a linear driving mechanism 2042 and a universal joint, the moving platform 2041 and the frame of the first section 201 are in an integrated structure, the fixed platform 2043 and the frame of the second section 205 are in an integrated structure, and two ends of the linear driving mechanism 2042 are respectively connected with the moving platform 2041 and the fixed platform 2043 through the universal joint. One linear driving mechanism 2042 corresponds to two universal joints, namely, a first end of the linear driving mechanism 2042 is connected with the movable platform 2041 through one universal joint, and a second end of the linear driving mechanism 2042 is connected with the fixed platform 2043 through the other universal joint. Further, the posture adjustment device 204 is a six-degree-of-freedom motion platform 2041 including six linear driving mechanisms 2042. For the posture adjusting device 204 arranged between any two sections of the internal welding machine, the sensor 4 detects and the posture adjusting device 204 is actively driven, namely, one side connected with the movable platform 2041 can be driven to adapt to the contour of the pipeline, so that the internal welding machine can freely walk in the pipeline without collision. For the preferred embodiment described above, the movable platform 2041 is mounted on the side of the nose mechanism, i.e., the movable platform 2041 is now positioned adjacent to the tension assembly 203 and the welding device 202, so that the attitude adjustment device 204 can flexibly adjust the nose mechanism (also including the tension assembly 203 and the welding device 202) to make the nose portion of the inner welder more adaptable to the pipe.

The sensor 4 may be used to collect pipe profile data of the location of the welder and the attitude adjustment device 204 may include a plurality of sensors 4 to collect overall pipe profile data.

The electric control module is used for calculating the target gesture of the first section 201 according to the pipeline profile data and performing calculation of a motion inverse solution algorithm on the target gesture to generate a length change signal of the linear driving mechanism 2042; the electrical control module is further configured to control the linear driving mechanism 2042 to perform telescopic motion by using the length change signal, so that the first section 201 is in the target posture. Specifically, the present embodiment may determine, according to the pipe profile data, a current relative position of the current pipe and the internal welding machine, and determine, according to the current relative position, a target posture of the first section 201. The target posture may be a posture that enables the internal welding machine to normally travel in the pipe without collision.

The posture adjusting device 204 provided in this embodiment is disposed between the first section 201 and the second section 205 of the internal welding machine, and because the movable platform 2041 and the frame of the first section 201 are in an integrated structure, and the fixed platform 2043 and the frame of the second section 205 are in an integrated structure, when the linear driving mechanism 2042 of the posture adjusting device 204 performs telescopic movement, the posture of the first section 201 can be changed. In the working process, the electrical control module in this embodiment calculates the target gesture of the first section 201 according to the pipeline profile data, and performs calculation of a motion inverse solution algorithm on the target gesture to generate a length change signal of the linear driving mechanism, so as to control the linear driving mechanism 2042 to perform telescopic motion through the length change signal, so that the first section 201 is in the target gesture. According to the embodiment, the gesture of the internal welding machine can be automatically adjusted according to the pipeline profile data, and the welding quality is improved.

As a possible embodiment, the above-mentioned attitude adjustment system includes a plurality of sensors 4, all the sensors 4 are uniformly distributed in the first section 201, all the sensors 4 are in the same plane, all the mounting positions of the sensors 4 are substantially in a plane which is perpendicular to the axis of the first section 201, and the sensors 4 are disposed toward the tensioning assembly 203. For example, the posture adjustment device 204 may include 3 sensors 4, each sensor 4 being distributed at 120 ° intervals in the first section 201 and disposed toward the pipe region on the peripheral side of the tension member 203.

As a possible embodiment, the attitude adjusting device 204 of the attitude adjusting system further includes a moving end mount 2044 and a fixed end mount 2045, and the universal joints include a first type of universal joint and a second type of universal joint. The movable end mounting base 2044 is fixed on the movable platform 2041 through bolts, the first type universal joint is fixed on the movable end mounting base 2044 through bolts, and the first end of the linear driving mechanism 2042 is connected with the first type universal joint through bolts; the fixed end mounting seat 2045 is fixed on the fixed platform 2043 through bolts, the second type universal joint is fixed on the fixed end mounting seat 2045 through bolts, and the second end of the linear driving mechanism 2042 is connected with the second type universal joint through bolts.

As a possible embodiment, the above-mentioned electrical control module includes a motion controller, a servo driver, and a servo motor. And a motion controller for calculating a target attitude of the first segment 201 according to the pipeline profile data, and performing calculation of a motion inverse solution algorithm on the target attitude to generate a length change signal of the linear driving mechanism 2042. And the servo driver is used for generating a corresponding pulse signal according to the length change signal issued by the motion controller. And the servo motor is used for rotating according to a pulse signal issued by the servo driver so as to drive the corresponding linear driving mechanism 2042 to perform telescopic movement until the first section 201 is in the target posture.

The sensor 4 installed on the first section 201 of the integrated intelligent pipeline welding machine shown in fig. 18 detects pipeline profile data and transmits the pipeline profile data to the motion controller, and the motion controller calculates the telescopic length of each linear driving mechanism 2042 in the gesture adjusting device 204, so as to control the motion of the moving platform 2041, thereby realizing the effect of active overbending of the first section 201 of the head of the welding machine.

Fig. 19 shows a posture adjustment system, which illustrates a sensor 4, an ethernet cable, a controller area network CAN, an electrical control cabinet, a motion controller, a digital module, other expansion modules, a dc power supply, a servo driver, a control system, and a posture adjustment device 204, where the posture adjustment device 204 may include a moving platform 2041, a universal joint, a linear driving mechanism 2042, a fixed platform 2043, and the like as shown in fig. 20. The control system comprises a control cabinet (which can be distributed on the internal welding machine), a multi-axis motion controller, a driver and a servo motor.

The above-mentioned posture adjustment device 204 operates as follows: the sensor 4 is used for detecting the pipeline profile data, then the pipeline profile data is sent to the control system, the control system converts the pipeline profile data into a length change signal of the linear driving mechanism 2042 through a motion inverse solution algorithm, and the motion controller sends a driving signal to the servo driver so as to drive the servo motor, so that the linear driving mechanism 2042 can change according to a given length to perform telescopic motion. The linear driving mechanism 2042 drives the movable platform 2041 to change its pose by a mechanism connected to the movable platform 2041 and the fixed platform 2043, and the movable platform 2041 moves along a track of the change in bending of the pipe.

Fig. 21 is a flowchart of a method for adjusting the posture of an internal welding machine according to an embodiment of the present application, where specific steps may include:

s301: acquiring pipeline profile data of the circumference side of a movable platform 2041 on a first section 201 of the inner welding machine;

referring to fig. 18, the internal welding machine includes a first section 201, a second section 205, and an attitude adjusting device 204, where a sensor 4 is disposed on the first section 201, and the sensor 4 is used to detect pipeline profile data near a moving platform 2041. For certain preferred embodiments of the system, the attitude adjustment device 204 is disposed between the bit mechanism and the body mechanism so that the movable platform 2041 is adjacent to the tension assembly 203, and the sensor 4 detects pipe profile data in the vicinity of the tension assembly 203 and the welding device 202.

The posture adjusting device 204 is disposed between the first section 201 and the second section 205, the posture adjusting device 204 includes a moving platform 2041, a fixed platform 2043, a linear driving mechanism 2042 and a universal joint, the moving platform 2041 is connected with the frame of the first section 201, the fixed platform 2043 is connected with the frame of the second section 205, and two ends of the linear driving mechanism 2042 are respectively hinged with the moving platform 2041 and the fixed platform 2043.

In a preferred embodiment, the sensor 4 is a stripe laser sensor, and laser stripes emitted by the sensor 4 irradiate on a pipeline, so that a laser contour line is formed on the pipeline, and an image of the laser contour line is collected for analysis processing, so that whether the current sensor 4 detects the end face of the pipeline can be known;

more specifically, the running gear on the second section 205 drives the second section 205 to run along the pipe towards the side where the first section 201 is located, the position of the sensor 4 on the conical head mechanism is located at the front side of the running direction relative to the tensioning assembly 203 and the welding device 202, in other words, the sensor 4 is located farther away from the second section 205 relative to the tensioning assembly 203 and the welding device 202, the emitting direction of the laser stripe of the sensor 4 is towards the tensioning assembly 203 and the side where the welding device 202 is located, and the emitting direction of the laser stripe of the sensor 4 is inclined to the axial direction of the tensioning assembly 203 and towards the radial outer side of the tensioning assembly 203, and the length direction of the laser stripe of the sensor 4 is located in a plane passing through the central axis of the tensioning assembly 203, further, the laser stripe irradiation area of the sensor 4 covers the radial outer side area where the welding device 202 is located, so that the pose of the first section 201 can be detected in real time and accurately adjusted to enable the welding device 202 to accurately face the center of the welding seam between the two pipes.

The laser stripe emitted by the sensor 4 irradiates on the pipeline to form a laser contour line, and the position and the posture of the first section 201 relative to the pipeline are different, so that the laser stripe can form laser contour lines with different shapes when irradiated on the pipeline. Specifically, the different deflection states of the central axis of the tension assembly 203 on the first section 201 relative to the central axis of the pipe will form laser contour lines with different shapes, for example, when the first section 201 is located in a straight pipe section of the pipe, when the central axis of the tension assembly 203 is completely coincident with the central axis of the pipe, the laser stripe emitted by the sensor 4 irradiates on the inner wall of the pipe to form a straight line, and when the central axis of the tension assembly 203 has a deviation included angle with the central axis of the pipe, the length direction of the laser stripe emitted by the sensor 4 is inclined to the axial direction of the pipe, so that the laser stripe emitted by the sensor 4 forms an arc-shaped laser contour line on the inner wall of the pipe.

More specifically, the laser contour lines formed by the three sensors 4 are sent to the controller, the control system analyzes the image of the laser contour lines formed by each sensor 4 to obtain corresponding control parameters, and the posture adjusting device 204 acts according to the control parameters for centering and concentricity, so that the first section 201 is maintained in a state that the central axis of the tensioning assembly 203 coincides with the central axis of the pipeline, that is, the first section 201 is maintained to be at the exact center of the section of the pipeline, and smooth running of the welding machine in the pipeline along the inner wall of the pipeline is ensured.

The sensor 4 for detecting the profile data may also be implemented by means of a laser distance measuring sensor, an image sensor or the like provided on the endocutter. In other possible embodiments, the sensor 4 may be disposed on the cone head mechanism, or may be disposed on or near part or all of the tightening unit, part or all of the welding device 202 of the tightening assembly 203, however, in consideration of timeliness of posture adjustment, it is preferable to dispose the sensor 4 at a position close to the advancing direction of the inner welding machine, and disposing the detection area of the sensor 4 near the tightening unit, the welding device 202 may better ensure effectiveness of posture adjustment.

If the uniformly distributed tensioning units and the central axes of the welding devices 202 deviate from the central axes of the pipelines, the detection feedback results of different image sensors and laser ranging sensors are different, and the corresponding signal changes are detected through the sensors, so that the internal welding machine can perform gesture adjustment in real time, and the gesture adjustment can be realized.

S302: calculating a target pose of the first segment 201 from the pipe profile data and generating an adjustment signal based on the target pose calculation;

referring to fig. 18 to 20, the present invention specifically includes:

based on the known sensor installation correction coefficients, converting the profile data scanned by each sensor 4 into corrected profile data in the first section 201 coordinate system;

Calculating the position and the posture of the current pipeline under the first section 201 coordinate system based on the correction contour data;

solving the pipeline mathematical model to obtain the pipeline pose information of the current pipeline under the first subsection 201 coordinate system;

the pose (i.e., the angle of deflection relative to the first section 201) and the position (i.e., the offset relative to the first section 201) existing between the pipe and the first section 201 are obtained and an adjustment signal is generated.

Further, since the sensor 4, the tension assembly 203 and the welding device 202 have a distance in the axial direction of the pipe, correction processing is required for the measurement error of the sensor 4 to ensure accuracy. In this embodiment, the sensor mounting correction factor is: each mounting design size and each sensor 4 actually mounted error measurement form a homogeneous transformation matrix. The contour data of each sensor 4 can be transformed into the first segment 201 coordinate system by multiplying the contour data scanned by each sensor 4 by the homogeneous transformation matrix.

Further converting the pipeline profile data acquired by each sensor 4 under the first subsection 201 coordinate system; then, calculating the position and the posture of the current pipeline under the coordinate system of the first section 201 based on the corrected contour data by using a best fitting algorithm;

And solving the pipeline mathematical model by utilizing an optimized objective function of a least square method to obtain the pipeline pose information of the current pipeline under the first section 201 coordinate system.

S303: the linear drive mechanism 2042 is driven based on the adjustment signal to bring the axis of the movable platform 2041 on the first segment 201 to a target attitude.

As shown in fig. 18 to 21, the posture adjustment device 204 provided in the present embodiment is disposed between the first section 201 and the second section 205 of the internal welding machine, and when the linear driving mechanism 2042 of the posture adjustment device 204 performs telescopic movement, the posture of the first section 201 can be changed. In the working process, the electrical control module in this embodiment calculates the target gesture of the first section 201 according to the pipeline profile data, and performs calculation of a motion inverse solution algorithm on the target gesture to generate a length change signal of the linear driving mechanism 2042, so as to control the linear driving mechanism 2042 to perform telescopic motion through the length change signal, so that the first section 201 is in the target gesture. According to the embodiment, the gesture of the internal welding machine can be automatically adjusted according to the pipeline profile data, and the welding quality is improved.

In the most ideal state, the central axis of the movable platform 2041 coincides with the central axis of the section of the pipeline where the movable platform 2041 is located, and at this time, the first section 201 of the inner welding machine is adapted to the pipeline just through the linear driving mechanism 2042 without collision interference when walking. In practical situations, it is not possible for the axis of the moving platform 2041 to perfectly coincide with the axis of the pipe section in which it is located, and the axis of the moving platform 2041 is now substantially coincident with or substantially parallel to the axis of the pipe section in which it is located, and is also encompassed by the subject poses described herein.

Further, after collecting the pipe profile data of the position of the internal welding machine by using the sensor 4, the following operations may be performed: determining the type of the pipeline at the position of the internal welding machine according to the pipeline profile data; if the pipeline type is an elbow, a step of calculating a target posture of the first section 201 according to the pipeline contour data is carried out, so that the internal welding machine is adapted to the pipeline internal contour in real time; if the pipe type is a straight pipe, the extension distance of all the linear driving mechanisms 2042 is controlled to be the same, so that the internal welding machine keeps stable running.

Based on the system, the internal welding machine with the gesture adjusting system can also reduce the advancing speed of the internal welding machine after determining the pipeline type of the position of the internal welding machine according to the pipeline profile data if the pipeline type is an elbow, so that the internal welding machine can operate more stably at the elbow, and the impact is reduced.

Referring to fig. 20, fig. 20 is a schematic structural diagram of an attitude adjusting device 204 according to an embodiment of the present application, which illustrates a fixed platform 2043 (connected to a second section 205 in fig. 18), a fixed end mounting base 2045, a universal joint, a linear driving mechanism 2042, a movable end mounting base 2044, and a movable platform 2041 (connected to a first section 201 in fig. 18); in the figure, the axis direction of the inner welder, which is the central axis of the fixed platform 2043, is the Z-axis direction, the horizontal direction perpendicular to the Z-axis is the X-axis direction, the vertical direction perpendicular to the X-axis is the Y-axis direction, X, Y, Z denotes a coordinate axis of a rectangular coordinate system, Φx represents roll and pitch, Φy represents yaw.

The above embodiments are further described by a specific posture adjustment method, where the adjustment method includes:

pipeline profile data acquired by the sensor 4;

splicing and converting pipeline profile data (namely, integral pipeline profile point cloud data) acquired by each sensor under a first subsection 201 coordinate system through a pre-measured sensor installation correction coefficient;

the sensor installation correction factor is: each structural mounting design dimension and each sensor 4 is a homogeneous transformation matrix of actual mounting error measurements. The contour data of each sensor 4 can be transformed into the first segment 201 coordinate system by multiplying the contour data scanned by each sensor 4 by the homogeneous transformation matrix. The specific process is as follows:

let one of the sensors 4 collect pipe profile data as a (x _i ，y _i 0) obtaining a homogeneous transformation matrix according to the installation design size and the installation error:

the Rot matrix consists of an included angle between a sensor coordinate system and a coordinate axis corresponding to the first subsection 201 coordinate system, and represents rotation transformation; the p-vector consists of the coordinate values of the origin of the sensor coordinate system in the first subsection 201 coordinate system, representing the translation transformation.

The spliced pipeline profile data are expressed as:

Wherein P (x) _i ，y _i ，z _i ) Representing overall pipe profile data, A,B. C. tubing profile data acquired by each sensor 4 is represented, T _A 、T _B 、T _C .. the homogeneous transformation matrix, x, for each sensor 4 _i X-axis coordinate, y representing the ith point on the pipe profile data _i Y-axis coordinate, Z, representing the ith point on the pipe profile data _i Representing the Z-axis coordinates of the i-th point on the pipe profile data.

Solving the correction profile data by using an optimized objective function of a least square method, and obtaining pipeline position information of the current pipeline under the first section 201 coordinate system, wherein the process is as follows:

the overall pipe profile data is P (x _i ，y _i ，z _i ) Where i=1, 2,..n, n denotes the number of points in the pipe profile data, P ₀ Representing a point (x ₀ ，y ₀ ，z ₀ ) One point on the pipe axis may also be denoted as P ₀ (x ₀ ，y ₀ ，z ₀ )，x ₀ X-axis coordinate, y representing a point on the pipeline axis ₀ Y-axis coordinate, z, representing a point on the pipeline axis ₀ The Z-axis coordinate of a point on the axis of the pipeline is represented by V, the axis vector of the pipeline can also be represented by V (a, b, c), a represents the coordinate of the axis vector V of the pipeline on the X-axis, b represents the coordinate of the axis vector V of the pipeline on the Y-axis, c represents the coordinate of the axis vector V of the pipeline on the Z-axis, R _i Representing contour point cloud data points P _i (x _i ，y _i ，z _i ) The distance to the pipe axis, the mathematical description of the pipe (i.e., the pipe mathematical model) is expressed as follows:

[c(y _i -y ₀ )-b(z _i -z ₀ )] ² +[a(z _i -z ₀ )-c(x _i -x ₀ )] ² +[b(x _i -x ₀ )-a(y _i -y ₀ )] ² ＝R _i ²

the following formula is used in this example as the optimization objective function F (X), where R represents the pipe radius:

solving the pose parameters of the pipeline: p (P) ₀ (x ₀ ，y ₀ ，z ₀ ) V (a, b, c), R are converted into corresponding extreme points X when F (X) is solved to obtain minimum values, wherein X= [ P ] ₀ ，V，R]。

Therefore, the nonlinear optimization problem is converted into X corresponding to the minimum value of F (X), expressed by the following formula:

x represents P in parameters of a pipeline mathematical model ₀ (x ₀ ，y ₀ ，z ₀ ) Represents a point on the axis of the pipe, V (a, b, c) represents the axial vector of the pipe, and R represents the vector of the radial composition of the pipe. Namely: x= [ X ] ₀ ；y ₀ ；z ₀ ；a；b；c；R]。

For the problem of extremum solving of the nonlinear function in the embodiment, the example constructs a Jacobian matrix to perform singular value decomposition by linearizing the nonlinear function, namely solving parameters in a nonlinear equation of a linear equation set iteration pipe mathematical model.

Specifically, the process of solving for X is as follows:

step 1: setting initial values of pipeline pose parameters

Wherein: />

Representing a point P on the axis of the pipe ₀ In this embodiment, the pipe offset may be expressed using the coordinates of a point on the pipe axis), in terms of>

Representing a point P on the axis of the pipe ₀ Coordinate estimation on the X-axis, +.>

Representing a point P on the axis of the pipe ₀ Coordinate estimation on Y-axis, +.>

Representing a point P on the axis of the pipe ₀ Coordinate estimation in Z-axis, +.>

An estimated value representing a pipe axis vector (the pipe offset angle in this embodiment may be represented using a pipe axis vector),>

coordinate estimation representing the pipe axis vector V on the X-axis,/->

Coordinate estimation value representing the pipe axis vector V on the Y-axis,/->

Coordinate estimation value representing the pipe axis vector V in the Z axis,/->

Representing an estimate of the radius of the pipe.

Step 2: in the optimization iteration process, in order to reduce the operand of deriving F (X), a method is established

For origin, ++>

The pipeline profile data P is a space rectangular coordinate system of a Z axis and is converted into a matrix U through homogeneous transformation _i (x _i ，y _i ，z _i ) Is converted into the coordinate system, so that +.>

These constants are taken into F (X) for which

Deriving and letting the derivative function 0, the following linear equation set is obtained:

wherein Jac is the Jacobian matrix obtained by bias derivation of the independent variable of f (X):

wherein, the vector D for expressing the fitting error is:

due to

Is an overdetermined equation set, and the vector D is not in the column space of the Jac matrix, so that the singular value decomposition method is used for solving the delta X. The iteration step Δx is expressed as the following equation, and the elements Δa, Δb, Δx, Δy, and Δr in Δx are coefficients of projection vectors of the linear expression vector D in the Jac column space:

Step 3: solving the linear equation to obtain a delta X matrix, updating iteration parameters, wherein T is the sign of a transposed matrix:

/>

step 4: judging whether the norm of the delta X is smaller than the accuracy required by iteration, if not, turning to the step 2, and continuing iteration; if yes, iteratively stopping outputting

The resolved X, i.e., pipe pose information, includes the pose (i.e., the angle of deviation from the first section 201) and the position (i.e., the offset from the first section 201) existing between the pipe and the first section 201. The gesture and the position are sent to a multi-degree-of-freedom adjusting mechanism (such as a six-degree-of-freedom moving platform) so that the axis of the first section 201 always coincides with the axis of the pipeline, and the first section 201 can be well adapted to an internal welding scene of walking movement in a bent pipeline while the internal welding machine moves forwards along the pipeline by the walking mechanism.

The posture adjustment device 204 (in the preferred embodiment, specifically, the six-degree-of-freedom motion platform) may further perform working space analysis on the target posture after obtaining the target posture, determine whether the target posture is within the working space of the posture adjustment device 204, if not, give an abnormality to the execution target, and modify the target posture to be the data closest to the original target posture within the executable working space range. The method comprises the steps of generating the expansion and contraction amount of each electric cylinder of the six-degree-of-freedom motion platform by combining inverse kinematics and trajectory curve constraint of the robot, transmitting the expansion and contraction amount of each electric cylinder to a motor driver of each electric cylinder through real-time network communication, and controlling the motor to rotate through a tricyclic PID (proportion integration differentiation). Meanwhile, each motor driver reports the current expansion and contraction amount of each shaft to the communication master station, and reports the actual pose of the current moving platform to the track planning and generator through the positive kinematic solution of the robot, so that the track planning and generator can adjust the planning pose in time according to the actual pose, and the control precision of the multi-degree-of-freedom adjusting mechanism is improved.

In the above-mentioned preferred embodiment, the second section 205 is an inner welding machine body, the fixed platform 2043 and the frame of the inner welding machine body are designed as an integrated structure, that is, the fixed platform 2043 is a part of the frame of the machine body, and the fixed platform 2043 also acts correspondingly when the machine body acts. The fixed platform 2043 is provided with mounting holes, the fixed end mounting seat 2045 is fixed on the fixed platform 2043 through bolts, the universal joint is fixed on the fixed end mounting seat 2045 through bolts, and the linear driving mechanism 2042 is connected with the universal joint through bolts.

Correspondingly, in this embodiment, the first section 201 is a conical head mechanism, and the moving platform 2041 and the frame of the conical head mechanism of the internal welding machine are designed as an integrated structure, that is, the moving platform 2041 is a part of the frame of the conical head mechanism, and the conical head mechanism also acts when the moving platform 2041 acts. The movable platform 2041 is provided with mounting holes, the movable end mounting base 2044 is fixed on the movable platform 2041 through bolts, and the linear driving mechanism 2042 is connected with the movable end mounting base 2044 through bolts.

Through the structure, when the pose of the movable platform 2041 relative to the fixed platform 2043 changes, the pose of the first section 201 relative to the second section 205 also changes, so that the inner welding machine can automatically turn under the control of the control system when encountering an elbow.

Referring to fig. 22, fig. 22 is a schematic structural diagram of an inner welding machine passing through an elbow pipe, which is provided in the embodiment of the present application, and the diagram shows a second section 205, an attitude adjusting device 204, a tensioning assembly 203, a first section 201, a sensor 4, a movable platform 2041, a linear driving mechanism 2042, a fixed platform 2043 and a pipeline.

Each linear driving mechanism 2042 in the gesture adjusting device 204 can realize independent telescopic movement in space, and the control system can control the motion of six degrees of freedom in the space by controlling the telescopic amount of the linear driving mechanisms 2042, so that the gesture of the motion platform 2041 is changed, and the aim of over-bending of the internal welding machine is fulfilled. The six degrees of freedom refer to translational movement of the platform along the three coordinate axes X, Y, Z, and rotational movement about the three coordinate axes (pitch φX, roll φY, yaw φZ, lateral X, longitudinal Z, vertical Y), respectively.

According to the motion state of the moving platform 2041, the response position and speed command signals of each linear driving mechanism 2042 are calculated, so that the motion of the moving platform 2041 is controlled, and the movement according to a preset track is ensured; when the movable platform 2041 reaches the desired position, the speed command signal of each linear drive mechanism 2042 is given to zero, and the movable platform 2041 is deactivated for precise point location control. When the inner welding machine encounters a bent pipe, the distance required to be acted by each linear driving mechanism 2042 is calculated according to the data input by the sensor 4, so that the movable platform 2041 moves to a proper position, and the phenomenon that the inner welding machine collides with the inner wall of a pipeline when the inner welding machine is excessively bent is avoided. When the inner welder walks on the straight pipe section, the movable platform 2041 is parallel to the fixed platform 2043, the linear driving mechanism 2042 extends for the same distance, and the initial posture is shown in fig. 18. When the inner welding machine is bent excessively, the movable platform 2041 rotates relative to the fixed platform 2043, and the lower bending is taken as an example, and the posture of the movable platform 2041 is shown in fig. 22.

In order to improve the real-time performance, high speed performance and use efficiency of the control system, the controller performs functional analysis on each control module, and combines the requirements of each function on the real-time performance in the control system, the following overall design scheme of the platform control system is adopted:

referring to fig. 23, fig. 23 is a general design diagram of a control system provided in an embodiment of the present application, which shows a control system including an upper computer management module (including an initialization module, a parameter setting module, a communication module, and an operation parameter display), a communication interface, a multi-axis motion controller, and a lower computer control module (including an electric mode, a test mode, an automatic mode, a servo driving module, and an I/O module).

The real-time module, i.e. the platform control system in the embodiment has strong real-time requirements. Mainly comprises the following steps: the device comprises a position servo module, a servo driving module and a fault detection module. In the running process of the platform, the position servo module is used for accurately controlling the positions of the shafts, and whether the executing mechanism can successfully complete the corresponding movement track is related; the servo driving module is used for monitoring the running state of each shaft and controlling the switching of the running state of each shaft; the fault detection module is used for detecting the running states of each shaft and the executing mechanism, and when a fault occurs, the purpose of protecting personnel safety and the platform from damage is achieved by immediately stopping the movement of the platform.

The control system can perform rationality analysis on the task according to the parameters input by the user, and has the function of shielding the control instruction of the super-motion range. The control system reasonably sets and monitors the motion parameter ranges such as the maximum speed and the maximum acceleration of the platform, and if the input instruction of the user is unreasonable, the motion platform can be implemented according to the set reasonable maximum motion parameter, so that continuous motion control is finished, and meanwhile, alarm prompt is also given.

Since the embodiments of the method portion correspond to the embodiments of the apparatus portion, the embodiments of the method portion are described with reference to the embodiments of the apparatus portion, which are not repeated herein.

The present application also provides a storage medium having stored thereon a computer program which, when executed, performs the steps provided by the above embodiments. The storage medium may include: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (Random Access Memory, RAM), a magnetic disk, or an optical disk, or other various media capable of storing program codes.

The application also provides an internal welding machine, comprising: a first section 201, a second section 205, and an attitude adjustment system;

The attitude adjustment system comprises an attitude adjustment device 204, an electrical control module and a sensor 4;

the posture adjustment device 204 is arranged between the first section 201 and the second section 205; the posture adjusting device 204 includes a moving platform 2041, a fixed platform 2043, a linear driving mechanism 2042 and a universal joint, wherein the moving platform 2041 and the frame of the first section 201 are in an integrated structure, the fixed platform 2043 and the frame of the second section 205 are in an integrated structure, and two ends of the linear driving mechanism 2042 are respectively connected with the moving platform 2041 and the fixed platform 2043 through the universal joint;

the sensor 4 is used for acquiring pipeline profile data of the position of the internal welding machine;

the electrical control module is configured to calculate a target gesture of the first section 201 according to the pipeline profile data, and perform calculation of a motion inverse solution algorithm on the target gesture to generate a length change signal of the linear driving mechanism 2042; the electrical control module is further configured to control the linear driving mechanism 2042 to perform telescopic motion by using the length change signal, so that the first section 201 is in the target posture.

Internal welding machine butt joint method

Fig. 24 is a flowchart of an inter-welding machine alignment method provided in an embodiment of the present application.

The specific steps may include:

s101: detecting Zhou Ceguan-channel profile data of the welding unit 304 of the internal welding machine, and judging whether the end face of the pipeline is detected or not based on the pipeline profile data;

the present embodiment is applicable to an internal welding machine provided with a sensor 4 and a multiple degree of freedom adjusting mechanism 303, and the internal welding machine may further include a cone head mechanism 301 and a body mechanism 302. Specifically, the sensor 4 may be disposed on an outer surface of the cone head mechanism 301, the multiple degree of freedom adjusting mechanism 303 may be disposed between the cone head mechanism 301 and the body mechanism 302, and the cone head mechanism 301 may be provided with a welding unit 304, a tension shoe 305, and a tension device 306.

Referring to fig. 25, fig. 25 is a schematic structural diagram of an internal welding machine provided in an embodiment of the present application, in which a cone head mechanism 301, a sensor 4, a multiple degree of freedom adjusting mechanism 303, a welding unit 304, a tension shoe 305, a tension device 306 and a body mechanism 302 are shown, and the body mechanism 302 includes a running device 308, a brake device 309 and a flexible front wheel 3010.

In this embodiment, a plurality of sensors 4 may be disposed on the cone head mechanism 301, so that each sensor 4 is used to collect profile data of a wall surface of a pipe, including profile data of an inner wall of the pipe and/or pipe profile data of a groove of an end surface of the pipe, which is located around the welding unit 304 of the internal welding machine.

In a preferred embodiment, the sensor 4 is a stripe type laser displacement sensor, and laser stripes emitted by the sensor are irradiated on the pipeline, so that a laser contour line is formed on the pipeline, and an image of the laser contour line is collected for analysis processing, so that whether the current sensor 4 detects the end face of the pipeline can be known.

More specifically, the running gear 308 on the body mechanism 302 drives the body mechanism 302 to run along the pipe towards the side where the conical head mechanism 301 is located, the position of the sensor 4 on the conical head mechanism 301 is located at the front side of the running direction relative to the tensioning device 306 and the welding unit 304, in other words, the sensor 4 is located farther away from the body mechanism 302 relative to the tensioning device 306 and the welding unit 304, the emitting direction of the laser stripe of the sensor 4 faces to the side where the tensioning shoe 305 and the welding unit 304 are located, the emitting direction of the laser stripe of the sensor 4 is inclined to the axial direction of the tensioning device 306 and faces to the radial outer side of the tensioning device 306, and the length direction of the laser stripe of the sensor 4 is located in a plane passing through the central axis of the tensioning device 306, further, the laser stripe irradiation area of the sensor 4 covers the radial outer side area opposite to the welding unit 304, so that the pose of the conical head mechanism 301 can be detected in real time and accurately adjusted to enable the welding unit to accurately face to the center of the welding seam between the two pipes 304.

The laser stripes emitted by the sensor 4 are irradiated on the pipeline to form laser contour lines, and the position and the posture of the cone head mechanism 301 relative to the pipeline are different, so that the laser stripes form laser contour lines with different shapes when being irradiated on the pipeline. Specifically, the different deflection states of the central axis of the tensioning device 306 on the cone head mechanism 301 relative to the central axis of the pipeline will form laser contour lines with different shapes, for example, when the cone head mechanism 301 is located in a straight pipe section of the pipeline, when the central axis of the tensioning device 306 is completely coincident with the central axis of the pipeline, the laser contour lines formed by the laser stripes emitted by the sensor 4 irradiating on the inner wall of the pipeline are in a straight line, and when the central axis of the tensioning device 306 and the central axis of the pipeline have a deviation included angle, the length direction of the laser stripes emitted by the sensor 4 is inclined to the axis direction of the pipeline, so that the laser stripes emitted by the sensor 4 form arc-shaped laser contour lines on the inner wall of the pipeline, and the laser contour images collected by the sensor 4 in real time can be matched with the preset groove images, so that the grooves are identified for alignment.

In a preferred embodiment of the method, the number of the sensors 4 is preferably 3, the sensors are uniformly distributed along the circumferential direction, when the laser images of the sensors 4 in the previous step change to be L-shaped, whether the sensors 4 detect the end face of the pipeline groove is judged according to whether the detected laser profile images are matched with the preset profile images or not, and in particular, the profile data of each sensor 4 are converted into a binary profile image through equal-proportion downsampling; matching the profile image with a preset groove profile image (such as a standardized groove image); if the profile image matches the pre-stored groove profile image (e.g., the similarity is greater than a preset value), then the groove may be determined to be detected.

More specifically, the laser contour lines formed by the three sensors 4 are sent to the controller, the controller analyzes the image of the laser contour lines formed by each sensor 4 to obtain corresponding control parameters, and the multi-degree-of-freedom adjusting mechanism 303 acts according to the control parameters coaxial with the pipeline, so that the cone head mechanism 301 is maintained in a state that the central axis of the tensioning device 306 coincides with the central axis of the pipeline, that is, the cone head mechanism 301 is maintained at the center of the section of the pipeline, and the welding machine in the pipeline is ensured to smoothly travel along the inner wall of the pipeline.

Meanwhile, the conical head mechanism 301 forms laser contour lines with different shapes when the positions of the conical head mechanism 301 relative to the end of the pipeline are different, the conical head mechanism 301 of the in-pipeline welding machine is kept in a state that the central axis of the tensioning device 306 coincides with the central axis of the pipeline, the conical head mechanism 301 walks along the pipeline, when the conical head mechanism 301 is completely positioned in the pipeline of the linear pipeline section or the tensioning device 306 and the welding unit 304 are completely positioned in the pipeline of the linear pipeline section, the laser stripes emitted by the sensor 4 only irradiate on the inner wall of the pipeline, so that the formed laser contour lines are in a straight line, and when the in-pipeline welding machine continues to travel until the laser stripes emitted by the sensor 4 irradiate on the groove at the end of the pipeline, the formed laser contour lines are in an approximately L shape, the shape of the laser contour lines is changed, therefore, the position condition of the cone head mechanism 301 of the welding machine in the pipeline relative to the pipeline port can be judged by analyzing and processing the image of the laser contour line, namely, the laser contour image acquired by the sensor 4 in real time can be matched and matched with a preset contour image (the preset contour image can be a standard laser contour line image formed by irradiating laser stripes to the end part of the pipeline), so that whether the sensor 4 scans and detects the end part of the pipeline or not is judged, namely, the position distance of the cone head mechanism 301 relative to the end part of the pipeline is known, further, the running system can be automatically controlled to stop, and the cone head pose is adjusted by the multi-degree-of-freedom pose adjusting mechanism through the output parameter control, so that the welding unit 304 in the cone head mechanism 301 of the internal welding machine is approximately stopped in the groove region 3012.

S102: when the sensor 4 for detecting the profile data and the plane where the end face of the pipeline is positioned meet the preset distance, controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline;

wherein a target stop position is determined from the pipe profile data such that the welding unit 304 in the cone head mechanism 301 moves into the groove region 3012 (i.e., the region where the pipe groove is located) when the welder moves to the target stop position. After the target stop position is determined, the running gear 308 of the internal welder may be controlled to stop moving such that the welding unit 304 and the expansion shoe 305 of the internal welder are stopped approximately near the pipe groove.

In order to improve the accuracy, the interference of the protrusions on the inner surface of the pipeline on the sensor detection images is avoided, and when the number of the sensors 4 on the end face of the pipeline is detected to be larger than 1, the expansion shoe 305 of the inner welding machine is determined to be basically positioned in the groove area 3012.

And controlling the internal welding machine to stop running along the axial direction of the pipeline by determining the distance relation between the plane where the groove is located and the sensor 4. When the contour image is matched with the prestored groove contour image (for example, the similarity is larger than a preset value), and when the number of the sensors 4 matched with the contour image is larger than 1, the grooves can be determined to be detected by the plurality of sensors 4, so that interference caused by uneven inner wall of the pipeline is avoided. Meanwhile, as the relative positions of the sensor 4 and the expansion shoe 305 are known and unchanged, the relative position relation between the expansion shoe 305 and the groove can be basically determined, and further the running gear 308 of the inner welding machine is controlled to stop, so that the welding unit 304 in the conical head mechanism 301 of the inner welding machine is stopped approximately in the groove area 3012.

When the number of the sensors 4 matched with the image is greater than 1, it can be determined that the plurality of sensors 4 detect grooves, at this time, the internal welding machine continues to walk for a distance in the pipeline due to time difference of signal processing, inertia and/or system preset control flow, and in the process of detecting the groove on the end face of the pipeline and determining that the groove on the end face of the pipeline is satisfied with the preset distance by the sensor 4 of the pipeline contour data and the plane where the end face of the pipeline is located, the system also processes the pipeline contour data to obtain the position relationship of the pipeline contour compared with the cone head mechanism 301, namely, in the image matching process, the shape of the groove can be determined to be approximately translated and rotated in the contour image, so that the plane where the welding unit 304 is located is approximately coplanar with the plane where the groove is located and the central axis of the pipeline on the periphery of the welding unit 304 is approximately coaxial by adjusting the multiple degree of freedom platform; if the welding unit 304 is already located at the groove of the pipe at this time, the central axis of the welding unit 304 is substantially coaxial with the central axis of the groove. Namely, when the corner detection is started and the contour shape of the bevel is optimally fitted, the matched bevel template image is basically positioned in the center of the contour image, and the posture of the cone head mechanism 301 is adjusted by controlling the multi-degree-of-freedom posture adjusting mechanism through output parameters. In this way, the multi-degree-of-freedom platform not only can realize the alignment, but also can adjust the position and the posture of the inner welding machine relative to the pipeline before the alignment, and when the axis of the inner welding machine is basically kept to be in line with the axis of the pipeline where the inner welding machine is positioned, the running system is automatically controlled to stop, so that the welding unit 304 in the conical head mechanism 301 of the inner welding machine is approximately stopped in the groove area 3012; the gesture adjustment can be more accurate and rapid for the deflection of the internal welding machine caused by the possible deflection or the bending of the pipeline in the walking process of the internal welding machine.

When the positional relationship between the sensor 4 and the plane on which the pipe end face is located reaches a preset distance relationship, the alignment position is finely adjusted by the multi-degree-of-freedom adjusting mechanism 303.

In other embodiments of the present application, whether the sensor 4 for detecting profile data and the plane where the pipe end face is located meet the preset distance may also be implemented by a laser ranging sensor, an image sensor, a magnetic flux sensor, etc. disposed on the endocutter. In other possible embodiments, the sensor 4 may be provided on the cone head mechanism 301, on or near the tension shoe 305 of the tension device 306, the welding unit 304, or on the fuselage mechanism 302; when the expansion shoe 305 and the welding unit 304 are positioned on or near the expansion shoe 305 and the welding unit 304, if the expansion shoe 305 and the welding unit 304 just extend out of the groove area 3012 of the pipeline, the distance between the expansion shoe and the inner wall of the pipeline, the image, the luminous flux and the magnetic flux (when the pipeline is a metal pipeline) all change, the corresponding signal change is detected by the sensor 4, so that the inner welding machine stops moving along the axial direction in the pipeline, and the sensor 4 and the plane on which the end face of the pipeline is positioned meet a certain distance.

Because the internal welding machine has larger volume and heavier dead weight, the internal welding machine is driven to perform the butt joint only by the travelling device 308, and the butt joint cannot be accurately realized, in the above embodiments, the internal welding machine can be stably stopped in the pipeline and the expansion shoe 305 is approximately positioned in the welding area through the steps, and then the automatic butt joint is realized through the following fine adjustment steps:

S103: and calculating the position relation between the sensor 4 and the end surface of the pipeline, and adjusting the multi-degree-of-freedom adjusting mechanism 303 between the conical head mechanism 301 and the machine body mechanism 302 of the internal welding machine through the pose information, so that the welding unit 304 on the conical head mechanism 301 of the internal welding machine is opposite to the groove to be welded, and the internal welding machine and the pipeline are relatively fixed.

After the internal welding machine moves to a target stop position, the position relation between the sensor 4 and the end face of the pipeline can be calculated from pipeline profile data, and angular point detection can be performed through an obtained profile image of the pipeline; obtaining rough difference coordinate values of all vertexes of the contour image, and performing multi-joint broken line fitting on the contour data by taking the rough difference coordinate values of all vertexes of the contour image as initial values to obtain accurate coordinates of all vertexes of the contour; and converting the accurate coordinates of each vertex of the profile into groove feature space coordinates under the coordinate system of the cone head mechanism 301, and further determining groove pose information of the pipeline groove in the coordinate system of the cone head mechanism 301. The pose information includes the deflection angle and offset data existing between the groove and the cone head mechanism 301. The multi-degree-of-freedom adjusting mechanism 303 between the conical head mechanism 301 and the machine body mechanism 302 of the internal welding machine is adjusted according to the pose information, and a welding torch in a welding unit 304 on the conical head mechanism 301 is opposite to a groove through the expansion and contraction amount of one or more electric cylinders in the multi-degree-of-freedom adjusting mechanism 303 in adjustment; after the position and the posture of the cone head mechanism 301 are adjusted, the tensioning device 306 extends out to enable the internal welding machine and the pipeline to be relatively fixed.

The coordinate system of the cone head mechanism 301 is the coordinate system of the cone head mechanism 301, and the pipe groove is the part of the pipe which needs to be welded.

Because the internal welding machine is used in a scene that the caliber of a pipeline is large generally, and the area to be welded formed by the butt joint grooves of two pipelines is narrow, the pipeline cannot be accurately butt-jointed due to fine deviation when the internal welding machine walks in the pipeline.

After the groove pose information is determined, the groove pose information may be input to the multiple degree of freedom adjusting mechanism 303, and then the pose of the cone head mechanism 301 is adjusted by using the multiple degree of freedom adjusting mechanism 303, so that a welding torch of a welding unit 304 on the cone head mechanism 301 is opposite to the welding seam center of the pipeline groove after the position is adjusted.

Further, the multiple degree of freedom adjusting mechanism 303 is a six degree of freedom motion platform including a plurality of electric cylinders; accordingly, the pose of the cone head mechanism 301 can be adjusted by: the groove pose information is input into the multi-degree-of-freedom adjusting mechanism 303, and the expansion and contraction amount of one or more electric cylinders is changed by utilizing the multi-degree-of-freedom adjusting mechanism 303 according to the groove pose information so as to adjust the pose of the cone head mechanism 301.

When the pose adjustment is completed, the expansion shoe 305 expands the pipe inner peripheral surface to fix the welding unit 304 relative to the pipe inner peripheral surface.

After the welding torch of the welding unit 304 is opposite to the welding seam center of the pipe groove, the expansion shoe 305 positioned in the pipe is expanded and tightly fixed on the inner wall of the pipe, and after the other pipe to be welded is butted from one side of the cone head mechanism 301, the expansion shoe 305 at the other side is stretched and tightly fixed, thus finishing the butt joint operation. In other embodiments in the art, after the welding torch of the welding unit 304 is aligned to the center of the welding seam of the pipe groove, the two sets of expansion shoes 305 may be sequentially or simultaneously expanded on the inner wall of the pipe after another pipe to be welded is aligned to the pipe groove, and the six-degree-of-freedom platform may be used to adjust the width of the interface between the two pipes to be welded to meet the welding requirement.

Through the mode, the welding torch of the welding unit 304 of the internal welding machine can be automatically adjusted to the position opposite to the center of the welding line of the groove of the pipeline under the butt-joint scene, so that the internal welding machine realizes high-precision automatic butt-joint, and further the welding quality is improved.

More specifically, the exact coordinates of each vertex of the contour may be determined by: constructing a groove contour mathematical model corresponding to the contour data by taking the coordinates of the angular points as initial values; and solving the contour mathematical model by utilizing an optimized objective function of a least square method to obtain the accurate coordinates of each vertex of the contour.

As a further embodiment corresponding to fig. 24, the operating situation of the internal welding machine can also be determined by the sensor 4. If the current working scene is a locating scene, the internal welding machine can further execute the following operations: performing splicing operation and coordinate system conversion operation on all the pipeline profile data acquired by the sensors 4 according to the sensor installation correction parameters to obtain overall pipeline profile data under the coordinate system of the cone head mechanism 301; determining the pipe pose information of the current pipe under the coordinate system of the cone head mechanism 301 according to the overall pipe profile data; the current pipeline is a pipeline corresponding to the pipeline profile data; and adjusting the pose of the cone head mechanism 301 by using the multi-degree-of-freedom adjusting mechanism 303 according to the pose information of the pipeline so as to enable the axis of the cone head mechanism 301 to coincide with the axis of the current pipeline. The overall pipeline profile data is a splicing result of the pipeline profile data acquired by each sensor 4, and is used for describing the overall profile shape of the inner wall of the pipeline.

Specifically, if the internal welder is provided with M sensors 4, the current working scenario of the internal welder may be determined as follows: collecting the pipeline profile data by using M sensors 4, and generating a binarized profile image corresponding to the pipeline profile data collected by each sensor 4; matching the binarized contour image corresponding to each sensor 4 with a preset groove contour image; if the number of the binarized contour images successfully matched is greater than or equal to N, judging that the current working scene of the internal welding machine is an opposite scene; if the number of the successfully matched binarized contour images is smaller than N, judging that the current working scene of the internal welding machine is a locating scene, namely a working scene walking along the axial direction of the pipeline. Wherein N is more than 0 and less than or equal to M.

In the above process, the binary contour image is matched with the preset groove contour image, and if the similarity between the binary contour image and part or all of the images of the preset groove contour image is greater than the preset similarity (for example, 90%), the binary contour image is judged to be successfully matched. According to the method, whether the current working scene is a contrast scene or a locating scene is judged according to the number of the binarized contour images successfully matched. In order to improve the detection accuracy of the working scene, n=m may be set so as to avoid interference caused by local protrusions of the inner wall of the pipeline. As a possible implementation, the present embodiment may uniformly arrange M (e.g., m=3) sensors 4 on the cone head mechanism 301, so as to improve the comprehensiveness of acquiring the pipe profile data.

The flow described in the above embodiment is explained below by way of an embodiment in practical use and with reference to fig. 26 to 29. Fig. 26 is a schematic partial enlarged view of a welding unit 304 and a groove in the alignment process according to an embodiment of the present application; fig. 27 is a schematic diagram of down-sampling groove contour data collected by a sensor according to an embodiment of the present application to convert the groove contour data into a picture; fig. 28 is a schematic diagram of a result of performing corner detection on a groove profile according to an embodiment of the present application; fig. 29 is a schematic diagram of a groove contour fitting result provided in an embodiment of the present application.

Shown in fig. 26 are a fixed steel pipe 3011, a beveled region 3012, a welding unit 304, and a tensioning device 306. The multi-sensor acquisition system comprises a stripe type laser displacement sensor acquisition head, a sensor controller and a network communication module; the alignment control processing flow comprises corner detection, optimal fitting of groove contours, determination of sensor correction coefficients, groove characteristic point splicing, groove pose calculation, adjustment control system of a cone head mechanism system, control of the work of a rear expansion boot 305 tensioning device, new pipe placement and control of the work of a front expansion boot 305 tensioning device.

The following two difficulties exist in the related art for the butt joint of the bent pipe: (1) In the process of shaping the bevel of the bent pipe, the bevel cutting surface cannot be perpendicular to the axis of the pipeline inevitably due to the existence of installation errors of a beveling machine; (2) When the pipe is aligned in the bent pipe, the front wheel of the cone head mechanism cannot be effectively attached to the pipe wall, so that an included angle is formed between the cone head mechanism and the axis of the pipe, and at the moment, the cone head mechanism of the internal welding machine is required to adjust the position and the posture of the internal welding machine along with the position and the posture of the groove, so that a welding torch in the welding unit 304 can be opposite to the center of the welding line. Aiming at the technical problems in the related art, the application provides an automatic alignment device and an alignment method thereof for an internal welding machine, which are used for improving the posture adjusting capability of a conical head mechanism of the internal welding machine when a machine body moves forwards and backwards to find an alignment area in the alignment process, and simultaneously, the factors such as personnel safety, alignment quality, equipment weight and the like can be considered.

Specifically, the automatic aligning device and the aligning method of the internal welding machine can be applied to welding scenes in pipelines of butt-jointed bent pipelines, the aligning device can flexibly adjust the gesture of the conical head mechanism 301, the device walks in the bent pipe with high adaptability, and a sensor detection system is used for providing feedback for the multi-degree-of-freedom adjusting mechanism 303 to achieve the purpose of accurate aligning. The embodiment performs pipeline profile data acquisition work for automatic alignment by a precise sensor detection system. The six-degree-of-freedom motion platform with high precision and high flexibility enables the conical head mechanism 301 to adjust the position and the posture of the conical head mechanism in an unconstrained mode within a certain range. The locating scene and the opposite scene can be stably distinguished through an image matching algorithm with rotation scaling invariance. By performing corner detection in image space, robust corner position estimation with high timeliness can be obtained. The characteristic point positions of the actual grooves can be accurately obtained through a contour fitting method based on a least square method. The designed product combining the multi-sensor acquisition system and the cone head mechanism posture adjustment system can be applied to the welding operation scene of the bent pipeline opposite port.

The automatic aligning device of the internal welding machine comprises: a cone head mechanism 301, a sensor 4, a multi-degree-of-freedom adjusting mechanism 303 and a body mechanism 302. The bit mechanism 301 includes a number of welding units 304 and a tensioning device 306. The sensor 4 is mounted on the frame of the cone head mechanism 301 using a plurality of laser vision sensors (e.g., stripe laser displacement sensors). The multiple freedom degree adjusting mechanism 303 is connected between the cone head mechanism 301 and the machine body mechanism 302, and the multiple freedom degree adjusting mechanism 303 comprises a plurality of electric cylinders. The multiple degree of freedom adjustment mechanism 303 can flexibly deflect and offset the cone head mechanism 301 relative to the machine body structure by controlling the length of each electric cylinder. The fuselage mechanism 302 includes mechanisms such as a running gear 308, a brake 309, flexible front wheels 3010, etc., which function to meet the demands of the welder for forward movement, backward movement, and stopping movement within the curved pipe.

The automatic butt joint method of the internal welding machine comprises the following steps:

step one, a plurality of laser vision sensors (such as 3 stripe type laser displacement sensors) are used for detecting Zhou Ceguan-channel profile data of the expansion shoe 305 of the internal welding machine, the pipeline profile data collected by each laser vision sensor are respectively converted into binary profile images through downsampling, and the binary profile images are matched with preset groove profile images.

In order to increase the data scene discrimination rate, the pipeline contour data needs to be downsampled, and in order to prevent image distortion, the image should be scaled according to an equal proportion. And if the sensor data is the coordinate value of the pipeline contour point, directly establishing a mapping relation between the contour coordinate value and the pixel coordinate, assigning a 1 value to the pixel where the coordinate value is located and assigning a 0 value to the background pixel, and obtaining a binarized contour image of the groove contour.

The binarized profile image and the preset groove profile image have translation (delta x, delta y), rotation delta alpha and scaling lambda transformation, wherein (delta x, delta y) represents translation quantity of an abscissa and an ordinate, delta alpha represents a rotation angle, and lambda represents a scaling coefficient. The transformation relationship between the two is as follows:

m′[x，y]＝t[λ(x·cosΔα+y·sinΔα)-Δx，λ(-x·sinΔα+y·cosΔα)-Δy]；

wherein m x, y is a contour image, m' x, y is a part of the contour image corresponding to a template (preset groove contour image), t x, y is a preset groove contour image, x represents an abscissa, y represents an ordinate, and fourier transformation is performed on two ends of the equation to obtain the following:

M′[u，v]＝λ ^-2 e ^{-2πj(uΔx+vΔy)} T[λ ^-1 (u·cosΔα+v·sinΔα)，λ ^-1 (-u·sinΔα+v·cosΔα)]；

M' u, v represents the result of the Fourier transform of M x, y; u and v represent the abscissa and the ordinate of the image coordinate system after the Fourier transform of the original image m' [ x, y ], namely the pixel position after the Fourier transform, so as to express the frequency and wave surface direction information of the original image; e represents a natural constant; j represents an imaginary number; t represents the result of Fourier transformation of the preset groove profile image T.

The above phase information is removed and expressed in log-polar coordinates as:

M[1gρ，α]＝λ ^-2 T[1gρ-1gλ，α-Δα]；

M[1gρ，α]representing the phase information e removed ^{-2πj(uΔx+vΔy)} And then carrying out the result of the logarithmic-polar coordinate conversion. ρ represents the polar diameter in the polar coordinate system. Alpha represents the image M [1g rho, alpha]In the logarithmic-polar coordinate system, α can be regarded as a reference with respect to an image that has not undergone rotation transformation in the present embodiment, and α—Δα represents a rotation of Δα with respect to the image.

The rotation delta alpha and the scaling lambda are calculated by a phase correlation algorithm from T [1g rho-1 g lambda, alpha-delta alpha ], the template image is transformed according to delta alpha and lambda parameters, and the translation quantity (delta x, delta y) is calculated by a phase correlation algorithm with the profile image. According to the translation amount and rotation, the multi-degree-of-freedom posture adjusting mechanism is adjusted, so that the axis of the cone head mechanism 301 is always kept near the axis of the pipeline when the groove contour image is in the center of the whole image, and collision with the pipe wall in the pipe outlet process of the cone head mechanism 301 is avoided.

The process can occur not only before the butt joint method, but also during the butt joint method, namely after judging whether the end face of the pipeline is detected or not and before controlling the inner welding machine driving mechanism to stop driving the inner welding machine along the axial direction of the pipeline, the translation amount and rotation obtained by the method can be used as the rough translation and rough rotation values of the pipeline profile compared with the cone head mechanism 301, so that the gesture adjustment is performed before the inner welding machine stops, and the butt joint can be more accurate and quick.

The method comprises the steps of performing splicing operation and coordinate system conversion operation on all pipeline profile data acquired by sensors according to sensor installation correction parameters to obtain overall pipeline profile data under a cone head mechanism coordinate system; determining the pipe pose information of the current pipe under the cone head mechanism coordinate system according to the overall pipe profile data; the current pipeline is a pipeline corresponding to the pipeline profile data; and adjusting the pose of the cone head mechanism 301 by utilizing the cone head mechanism pose adjusting mechanism according to the pipeline pose information so as to enable the axis of the cone head mechanism 301 to coincide with the axis of the current pipeline. The overall pipeline profile data is a splicing result of the pipeline profile data acquired by each sensor 4, and is used for describing the overall profile shape of the inner wall of the pipeline. Splicing and converting the pipeline profile data (namely, integral pipeline profile point cloud data) acquired by each sensor 4 under a cone head mechanism coordinate system through the sensor installation correction coefficient obtained by pre-measurement;

The sensor installation correction factor is: each structure is installed and designed to form a homogeneous transformation matrix with the actual installation error measured value of each sensor. The contour data of each sensor 4 can be converted into the cone head mechanism coordinate system by multiplying the contour data scanned by each sensor 4 by the homogeneous conversion matrix. The specific process is as follows:

wherein Rot represents a matrix of rotation transformation, and the matrix is composed of included angles of corresponding coordinate axes of a sensor coordinate system and a cone head mechanism coordinate system; the p vector is composed of coordinate values of the origin of the sensor coordinate system under the coordinate system of the cone head mechanism, and represents translation transformation.

The spliced pipeline profile data are expressed as:

wherein P (x) _i ，y _i ，z _i ) Representing overall pipe profile data A, B, c. representing pipe profile data acquired by each sensor 4, T _A 、T _B 、T _C .. the homogeneous transformation matrix for each sensor 4.

Step two: and controlling the stop position of the walking device 308 of the internal welding machine according to the contour image matching result, so that the welding unit 304 in the cone head mechanism 301 is stably stopped in the groove area 3012. Fig. 26 shows the stop position of the welding unit 304 in the bevel area 3012. When the image matching shows that the end face of the pipeline is detected and the matching result is larger than 1, whether the position relation of the plane where the sensor 4 and the end face of the pipeline are located reaches a preset distance relation or not is calculated, and when the preset distance relation is met, the internal welding machine is controlled to stop walking, so that the welding unit 304 is stopped in the groove area 3012.

Step three: based on the position of the internal welding machine after stopping, acquiring contour data at the moment through each sensor 4, performing corner detection on a contour image (namely an image corresponding to the pipeline contour data) obtained through binarization downsampling, and obtaining rough difference coordinates of each characteristic point in the contour image

The rough coordinates of each characteristic point of the stable outline can be obtained by using a corner detection algorithm, and the corner detection result is shown in fig. 25.

Taking the rough difference coordinate value of the characteristic points in the contour image as an initial value, and carrying out optimal fitting on the contour data to obtain the accurate coordinates of the groove contour characteristic points (namely groove characteristic points);

specifically, the process of performing fitting calculation on the pipeline profile data based on the least square method by taking the coordinates of the angular points as initial values to obtain the groove characteristic points is as follows:

constructing a groove contour mathematical model corresponding to the pipeline contour data by taking coordinates of the corner points as initial values, wherein the groove contour mathematical model y (x) can be expressed as:

n represents the number of straight line segments;

a represents the intercept of y (x);

k _j represents the slope difference between two adjacent front and rear line segments, j=1, 2,..n-1;

b _j the abscissa indicating the position of the feature point, j=1, 2,..n-1;

ε(x-b _j ) Represents if x.gtoreq.b _j Epsilon (x-b) _j ) =1, otherwise ε (x-b _j )＝0；

Converting the rough difference coordinates of each characteristic point of the obtained contour image into

As an initial estimate, the symbol "ζ" is used to distinguish between the initial value and the final value of the above letter.

Solving the profile mathematical model by utilizing an optimized objective function of a least square method, and obtaining the groove characteristic points by the following steps:

the groove profile mathematical model y (X) is a nonlinear function by creating the following optimization function F (X):

solving for y by solving for the minimum of the nonlinear function(x) Model parameters of (2): a. b _j 、k _j 。

The fitting result y (x) is plotted as shown in fig. 29, and the point where the slope of the function changes is used as the groove characteristic point and the groove characteristic point.

And splicing and converting the accurate characteristic point coordinates of the groove profile in each sensor coordinate system to the cone head mechanism coordinate system, obtaining the space coordinates of the groove characteristic points, obtaining a homogeneous transformation matrix by measuring the installation size, and converting the groove characteristic point coordinates in each sensor 4 to the cone head mechanism coordinate system.

Calculating the position and the posture of the current circular pipeline groove under the coordinate system of the cone head mechanism according to the space coordinates of the groove characteristic points;

recording groove characteristic points as A _i (x _i ，y _i ，z _i ) When i=3, three groove feature points a are extracted ₁ 、A ₂ And A ₃ . The following formula is used to obtain the data parameters of the circle where the groove is located:

1. normal vector of groove circle:

wherein->

2. Center coordinates:

wherein->

The subscripts x, y, z of R1 in the above formula represent the coordinates of the respective coordinate axes.

3. Radius of circle R:

R＝||o-A ₁ ||。

according to the normal vector (namely, the deflection angle relative to the cone head mechanism 301) and the circle center coordinate (namely, the deflection relative to the cone head mechanism 301) of the plane and the outline of the pipeline groove, the multi-degree-of-freedom adjusting mechanism 303 (namely, the six-degree-of-freedom moving platform) is used, so that the welding torch of the welding unit 304 on the cone head mechanism 301 can be opposite to the center of the groove weld.

After the pose of the cone head mechanism 301 is adjusted, the expansion boots 305 in the rear expansion mechanism on the cone head mechanism 301 extend out to cling to the inner wall of the pipeline; and installing a new pipe to be aligned, wherein an expansion shoe 305 in a front expansion mechanism on the cone head mechanism 301 extends out to cling to the inner wall of the pipeline, and aligning is completed.

According to the embodiment, the groove model parameters are solved by constructing the nonlinear optimization problem, so that the interference of random errors introduced in the measuring process of the sensor can be well restrained. Meanwhile, the groove mathematical model is used, so that the extraction precision of groove characteristic points can be higher than the image resolution of the stripe type laser displacement sensor, and powerful guarantee is provided for the alignment precision of the internal welding machine to be less than 0.2 mm.

The alignment device provided by the embodiment is based on the cooperation of the sensor 4 and the multi-degree-of-freedom adjusting mechanism 303, realizes groove pose detection and feedback to the multi-degree-of-freedom adjusting mechanism 303, and the multi-degree-of-freedom adjusting mechanism 303 calculates and controls the expansion and contraction amount of the electric cylinder through forward and backward kinematics, so that the position and the pose of the cone head mechanism 301 in a pipeline are controlled, and the effect of flexibly aligning the welding requirements is achieved. The embodiment constructs a laser vision sensor measurement system, and collects the spatial position information of a target object in the pipeline butt operation process of the internal welding machine; the position and the pose of the pipeline and the groove are calculated through an image data processing unit; the calculated pose information is fed back to the multi-degree-of-freedom adjusting mechanism 303, and the spatial pose of the cone head mechanism 301 is adjusted in real time.

In the alignment method provided by the embodiment, the geometry of the groove of the pipeline is accurately described by using the mathematical model of the groove, the deflection angle and the deflection existing between the groove and the cone head mechanism 301, and the groove or the numerical solution containing part of the geometric shape of the pipeline profile is iterated by an optimization method, so that the random error of the environmental interference factors and the processing and manufacturing errors of the pipeline and the groove can be well restrained.

In the process of extracting the precise coordinates of the outline vertexes, the traditional Douglas-Peucker polygon fitting adopts the method of comparing the distance values of the outline points from the outline to obtain partial special points, and the special points are used as the characteristic points of the polygon outline, so that the following difficulties exist in the practical application: on one hand, the sharp triangle shape cannot be presented when the profile of the intersection angle of two straight lines is measured due to the reflection characteristic of light, so that the actual groove profile corner point is not on the laser profile data; on the other hand, profile data always has jumps due to the influence of laser sensor field of view occlusion, steep profile edge blurring, stray light interference, etc. According to the embodiment, the jump of the contour data can be effectively restrained by using least square fitting, and meanwhile, the actual groove characteristic points which are not in the laser contour data can be accurately estimated by introducing the least square method into the contour fitting. In the embodiment, an initial iteration value is required to be set for a feature point in the process of contour fitting, contour data are converted into an image space by sampling groove contour data in an equal proportion in the X, Y direction, and coarse difference estimated coordinates of the contour feature point are obtained by utilizing Hanis corner detection. Therefore, the data processing amount is reduced, and meanwhile, the robust estimated value of the groove characteristic point coordinate can be obtained. And (3) bringing the estimated value into an initial value of groove contour fitting iteration, so that an iteration result can be converged to a true value of groove characteristic joint point coordinates. In the embodiment, the vertex of the groove is extracted, the position and the posture of the circle where the groove is located under the coordinate system of the cone head mechanism are calculated, and the position and the posture of the cone head mechanism are fed back to the multi-degree-of-freedom adjusting mechanism 303 (a six-degree-of-freedom moving platform) to adjust the posture of the cone head mechanism in real time, so that the flexibility of alignment is greatly improved.

The embodiment of the application provides an internal welding machine is to mouthful device, the internal welding machine that internal welding machine is to mouthful device is located is including setting up in the sensor 4 of conical head mechanism 301 to and set up in multi freedom adjustment mechanism 303 between conical head mechanism 301 and the fuselage mechanism 302, internal welding machine is to mouthful device includes:

expansion shoes 305 circumferentially distributed along the inner welder head,

a sensor 4 for detecting profile data of the welding unit 304 Zhou Ceguan channels of the internal welding machine, and judging whether the end face of the pipeline is detected or not based on the profile data;

the control system is used for controlling the internal welding machine driving mechanism to stop driving the internal welding machine along the axial direction of the pipeline when the sensor 4 for detecting the profile data and the plane where the end face of the pipeline is positioned meet the preset distance;

the control system is also used for calculating the position relation between the sensor 4 and the end face of the pipeline to obtain pose information, and the pose information is used for adjusting the multi-degree-of-freedom adjusting mechanism 303 between the inner welding machine conical head mechanism 301 and the machine body, so that the inner welding machine conical head mechanism 301 is opposite to the groove to be welded, and the inner welding machine and the pipeline are relatively fixed.

Since the embodiments of the apparatus portion and the embodiments of the method portion correspond to each other, the embodiments of the apparatus portion are referred to the description of the embodiments of the method portion, and are not repeated herein.

The present application also provides a storage medium having stored thereon a computer program which, when executed, performs the steps provided by the above embodiments. The storage medium may include: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a Random access Memory (Random AccessMemory, RAM), a magnetic disk, or an optical disk, or other various media capable of storing program codes.

The application also provides an internal welding machine, which comprises a conical head mechanism 301, a machine body mechanism 302, a sensor 4, a multi-degree-of-freedom adjusting mechanism 303, a memory and a processor, wherein the sensor 4 is arranged on the conical head mechanism 301, the multi-degree-of-freedom adjusting mechanism 303 is arranged between the conical head mechanism 301 and the machine body mechanism 302, a computer program is stored in the memory, and the processor realizes the steps provided by the above embodiments when calling the computer program in the memory.

The foregoing embodiments are described in an incremental manner, and each embodiment is mainly described for differences from other embodiments, so that identical and similar parts of the embodiments are referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant points refer to the description of the method section.

The foregoing is merely a preferred embodiment of the present invention, and it should be noted that the above-mentioned preferred embodiment should not be construed as limiting the invention, and the scope of the invention should be defined by the appended claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and such modifications and adaptations are intended to be comprehended within the scope of the invention.

Claims

1. An in-pipeline welding machine is characterized by comprising a machine head (1), a machine body (2) and a first connecting mechanism (3);

the machine head (1) is provided with a tensioning mechanism (11) and a welding mechanism (12);

a walking system for walking in the pipeline is arranged on the machine body (2);

the machine head (1) is connected with the machine body (2) through a first connecting mechanism (3), and the first connecting mechanism (3) has controllable movable degree of freedom so that the machine head (1) and the machine body (2) can relatively deflect.

2. The in-pipe welder according to claim 1, characterized in that the first connecting mechanism (3) comprises a static end (31) and a movable end (32), the static end (31) is connected with the machine body (2), the movable end (32) is connected with the machine head (1), and a plurality of movable members (33) are arranged in parallel between the static end (31) and the movable end (32) so as to enable relative movement between the static end and the movable end.

3. The in-pipe welder according to claim 2, characterized in that the movable member (33) is a linear telescopic member, one end of the linear telescopic member is movably connected with the stationary end (31), and the other end is movably connected with the movable end (32).

4. The in-line welder according to claim 1, characterized in that the first connection mechanism (3) is a parallel or series motion mechanism, the first connection mechanism (3) having two to six degrees of freedom.

5. The in-pipe welder according to claim 1, further comprising a sensor (4) arranged on the machine head (1) and used for detecting a pipe, wherein the control system receives the collected data detected by the sensor (4) and performs analysis processing to obtain control parameters, and the first connecting mechanism (3) acts according to the control parameters to adjust the pose of the machine head (1).

6. The in-pipeline welding machine according to claim 5, wherein the sensors (4) are circumferentially arranged on the machine head (1) at intervals, and the central axis of the circumference where the sensors (4) are located coincides with the central axis of the tensioning mechanism (11).

7. The in-line welder of claim 5, wherein the sensor (4) is a striped laser displacement sensor to detect the collected pipe profile data.

8. The in-line welder according to claim 5, characterized in that the control system comprises a coaxial unit for analyzing the acquired data detected by the processing sensor (4) to obtain control parameters for the coaxial, and the first connection mechanism (3) acts according to the control parameters for the coaxial so that the central axis of the welding mechanism (12) on the head (1) coincides with the central axis of the pipe at the position of the welding mechanism (12).

9. The in-line welder according to claim 5, characterized in that the control system comprises an interface unit that analyses the acquired data to obtain control parameters for interface, the first connection mechanism (3) acting according to the control parameters for interface to bring the welding mechanism (12) in direct opposition to the centre of the weld between the two lines to be butted.

10. The in-line welder of claim 9, wherein the interface unit comprises:

the scene judging module is used for analyzing and processing the data acquired by the sensor (4) to judge whether the data are in the opposite scene of the end part of the pipeline acquired by the sensor (4);

the metering module analyzes and processes the acquired data detected by the sensor (4) when the metering module is in a butt-joint scene so as to obtain the distance from the sensor (4) to the plane where the end part of the pipeline is positioned;

The parking module sends out an instruction for controlling a walking system to park the machine body (2) when the distance from the sensor (4) to the plane where the end part of the pipeline is positioned reaches a walking stopping condition;

and the contra-opening fine tuning module is used for analyzing and processing the data acquired by the sensor (4) under the parking state of the machine body (2) to obtain control parameters for fine tuning, and the first connecting mechanism (3) acts according to the control parameters for fine tuning so that the welding mechanism (12) is opposite to the center of a welding seam between two pipelines to be butted.

11. The in-pipe welder according to claim 1, characterized in that the travelling system comprises a travelling mechanism (51), the travelling mechanism (51) comprises a plurality of travelling wheel assemblies (511) arranged at intervals along the circumferential direction of the machine body (2), and the travelling wheel assemblies (511) are connected to a tightening mechanism (512) arranged on the machine body (2).

12. The in-pipe welder as claimed in claim 11, wherein the walking wheel assemblies (511) are provided with two walking wheel assemblies and distributed on two sides of the machine body (2) in the diameter direction, and the tightening mechanism (512) is a tightening hydraulic cylinder connected between the walking wheel assemblies (511) on two sides.

13. The in-line welder according to claim 11, characterized in that each traveling wheel assembly (511) is provided with a traveling motor (513), and that the traveling wheel assemblies (511) are electronically differentially controlled when over-bent.

14. The in-pipe welder according to claim 1, wherein the traveling system comprises a brake mechanism (52), the brake mechanism (52) comprises a brake cylinder (521), a brake block (522) and a holding elastic member (523), the brake block (522) is driven by the brake cylinder (521) to switch between a braking position and a releasing position, and the brake block (522) is further connected with the holding elastic member (523) for driving the brake block (522) to be held in a braking position.

15. The in-pipe welder according to claim 1, characterized in that the running system comprises a flexible wheel assembly (53), the flexible wheel assembly (53) comprises a wheel (531), a wheel seat (532) and an elastic assembly (533), the wheel (531) is arranged on the wheel seat (532), the wheel seat (532) is hinged on the machine body (2), a rotation plane of the wheel seat (532) is along a radial direction of the machine body (2), and the elastic assembly (533) is connected between the wheel seat (532) and the machine body (2).

16. The in-line welder of claim 15, wherein the flexible wheel assembly (53) further comprises an angle adjustment motor (534) coupled to the wheel (531) provided on the wheel mount (532), the angle adjustment motor (534) steering adjusts a direction of travel of the wheel (531).

17. The in-pipe welder according to claim 1, further comprising a battery unit (6), the battery unit (6) powering the tensioning mechanism (11), the welding mechanism (12), the running system and the first connection mechanism (3).

18. The in-pipe welder according to claim 1, characterized in that the machine body (2) is divided into a plurality of sections along the pipe axis direction, adjacent sections are connected by a second connecting mechanism (10), and the second connecting mechanism (10) is a deflectable connecting mechanism.

19. The in-pipe welder of claim 18, characterized in that the second connection mechanism (10) includes a first end (101), a second end (102), a universal joint (103) and a flexible connection member (104), the universal joint (103) and the flexible connection member (104) are connected between the first end (101) and the second end (102), the flexible connection member (104) is distributed in a plurality of circumferential directions of the universal joint (103), the first end (101) is connected with a previous section, and the second end (102) is connected with a next section.