CN116968054A - Large-scale pressure equipment weld joint surface and near surface defect repairing and repairing integrated robot and operation method thereof - Google Patents
Large-scale pressure equipment weld joint surface and near surface defect repairing and repairing integrated robot and operation method thereof Download PDFInfo
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- CN116968054A CN116968054A CN202311173464.8A CN202311173464A CN116968054A CN 116968054 A CN116968054 A CN 116968054A CN 202311173464 A CN202311173464 A CN 202311173464A CN 116968054 A CN116968054 A CN 116968054A
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- 230000007547 defect Effects 0.000 title claims abstract description 161
- 238000000034 method Methods 0.000 title claims abstract description 46
- 238000005498 polishing Methods 0.000 claims abstract description 292
- 230000009194 climbing Effects 0.000 claims abstract description 72
- 238000001514 detection method Methods 0.000 claims abstract description 39
- 238000007517 polishing process Methods 0.000 claims abstract description 11
- 239000007788 liquid Substances 0.000 claims description 89
- 238000003466 welding Methods 0.000 claims description 78
- 238000003860 storage Methods 0.000 claims description 65
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 49
- 239000000725 suspension Substances 0.000 claims description 45
- 238000003756 stirring Methods 0.000 claims description 36
- 238000005507 spraying Methods 0.000 claims description 31
- 230000008439 repair process Effects 0.000 claims description 27
- 238000012544 monitoring process Methods 0.000 claims description 22
- 239000000523 sample Substances 0.000 claims description 21
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 3
- 230000015556 catabolic process Effects 0.000 claims description 3
- 238000006731 degradation reaction Methods 0.000 claims description 3
- 238000009826 distribution Methods 0.000 claims description 3
- 238000011156 evaluation Methods 0.000 claims description 3
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
Abstract
The invention relates to the technical field of equipment overhaul, in particular to a large-scale pressure-bearing equipment weld joint surface and near-surface defect repairing and rechecking integrated robot and an operation method thereof. The defect positioning is carried out on the weld joint through the driving wall climbing robot, the length and the shape of the defect are displayed, the laser navigator is used for measuring the depth of the defect, the polishing head is controlled to carry out local polishing operation, the depth is measured in the polishing process, the polishing and detection integrated operation is realized, and the working efficiency is improved.
Description
Technical Field
The invention relates to the technical field of equipment overhaul, in particular to a large-scale pressure-bearing equipment weld joint surface and near-surface defect repairing and rechecking integrated robot and an operation method thereof.
Background
The large-scale pressure-bearing equipment is key special equipment of national strategy, taking a large spherical tank as an example, and the large spherical tank needs to be detected periodically every 3-6 years according to relevant regulations of China. Before detection, tank equipment is stopped, toxic gas-liquid replacement is carried out, a scaffold is built on the inner and outer scaffold of the spherical tank, an maintainer climbs on the scaffold to carry detection equipment for detection, for example, when a widely-used magnetic powder detection technology is adopted for surface or near-surface detection, magnetic suspension with proper proportion is sprayed, and a handheld instrument is used for detection and visual inspection and black light lamp observation to distinguish defects.
At present, for overhauling large-scale pressure equipment, the magnetic powder detection robots of the large-scale pressure equipment can respectively carry out magnetic powder detection on surface defects, if the magnetic powder detection is totally qualified, the full-automatic operation detection of the robots can be completely realized, the step of building a scaffold can be omitted, the operation time and the cost are greatly reduced, and the personal safety in the operation process can be ensured.
However, the conventional work robot has the following technical problems in performing the magnetic particle inspection work: some surface defects can be detected by partial large-scale pressure equipment during magnetic powder detection, so that the problem that welding seam repair is still needed manually after the surface defects are found is generated, the defects that a scaffold is needed to be built and the scaffold is needed to be lifted for manually polishing the welding seam are also needed to be detected again, the scaffold building link which is omitted in the front is made to lose meaning, the operation time and the operation cost are difficult to be greatly reduced, and the personal safety in the operation process can be ensured.
Disclosure of Invention
The invention mainly aims to overcome the defects in the prior art and provides a large-scale pressure-bearing equipment weld joint surface and near-surface defect repairing and reinspection integrated robot and an operation method thereof. The defect positioning is carried out on the weld joint through the driving wall climbing robot, the length and the shape of the defect are displayed, the laser navigator is used for measuring the depth of the defect, the polishing head is controlled to carry out local polishing operation, the depth is measured in the polishing process, the polishing and detection integrated operation is realized, and the working efficiency is improved.
The technical scheme adopted by the invention for realizing the technical purpose is as follows: the integrated robot for repairing and rechecking the defects on the surface and near surface of the welding seam of large-scale pressure equipment comprises a wall climbing robot, wherein the wall climbing robot comprises an adsorption module and a wall climbing travelling mechanism;
A control box and a magnetic suspension stirring and spraying device are fixedly arranged above a bottom plate of the wall climbing robot, a cross magnetic yoke is fixedly arranged below the bottom plate, and a black light lamp and a video detection system are arranged below a cross magnetic yoke iron core beam;
a polishing device and a constant force polishing control system are fixedly arranged in front of the wall climbing robot, and a laser automatic navigator is fixedly arranged on the polishing device;
the laser automatic navigator has two functions, namely, the robot can automatically walk along a welding line to reach a welding defect position, the function is started when the robot polishes and moves and when the robot detects and moves, the array laser method is adopted to measure geometric dimension parameters of a pit surface, the wall climbing robot walks forwards to obtain the three-dimensional geometric dimension parameters of the pit surface in real time, although the geometric dimension of the polished pit surface is accurately predicted through polishing depth control of a polishing head, the geometric dimension parameters of the pit can be accurately obtained through laser measurement, and therefore accurate safety assessment is carried out on the pit.
A fixed-point thickness measuring device is fixedly arranged at the rear part of the wall climbing robot;
a dustproof baffle plate is arranged between the polishing device and the cross magnetic yoke;
When the wall climbing robot works in the spherical tank, the wall climbing robot is connected with a falling protector which is fixedly connected to a flange at the top of the spherical tank;
an automatic tracking cradle head is arranged at the bottom of the interior of the spherical tank, the automatic tracking cradle head is connected with an external operation platform through a transmission cable, and the external operation platform is connected with a control box on the wall climbing robot through a shielding cable;
the automatic tracking cloud platform is used for monitoring the working condition of the wall climbing robot, the external operation platform is used for controlling the action of the wall climbing robot, and the external operation platform comprises display equipment for displaying the detection result of the video detection system and external input equipment for controlling the robot through the singlechip.
Preferably, the wall climbing travelling mechanism comprises a driving wheel, a driven wheel, a driving shaft mounting piece and a driving motor, and light source targets are arranged on two opposite sides of the wall climbing travelling mechanism.
Preferably, the magnetic suspension stirring and spraying device comprises a stirring device, a liquid storage tank, a spraying device and a control device;
the bottom surface of the liquid storage tank is fixedly communicated with a liquid suction pipe, the liquid suction pipe is respectively communicated with a stirring device and a spraying device, and the stirring device and the spraying device are respectively electrically connected with a control device; the stirring device is used for stirring the magnetic suspension of the liquid storage tank, the spraying device is used for spraying the magnetic suspension, and the control device is used for respectively controlling the starting and stopping of the stirring device and the spraying device;
The stirring device comprises a first water pump, a nozzle and a liquid return pipe;
the first water pump and the nozzle are communicated with the bottom surface of the liquid storage tank through the liquid return pipe and the liquid suction pipe, the first water pump is electrically connected with the control device, the first water pump pumps the magnetic suspension with high concentration out of the bottom of the liquid storage tank and discharges the magnetic suspension through the nozzle, and the nozzle is arranged in the liquid storage tank, the spraying direction of the nozzle is parallel to the bottom surface of the liquid storage tank and tangential to the vertical surface of the liquid storage tank so as to enhance the mixing effect;
the spraying device comprises a second water pump, a transfusion tube and a spray head;
the second water pump, the spray head and the bottom surface of the liquid storage tank are communicated through the infusion tube and the liquid suction tube, the second water pump is electrically connected with the control device, and the second water pump pumps out mixed magnetic suspension from the liquid storage tank and discharges the mixed magnetic suspension through the spray head.
Preferably, a mixing system is further arranged inside and outside the liquid storage tank, the mixing system comprises two groups of water baffles arranged inside the liquid storage tank, the water baffles are slidably connected to the upper half part of the liquid storage tank through guide rails, one side of each water baffle is fixedly connected with a pull plate, each pull plate penetrates through the water baffles on opposite sides and extends to the outside of the liquid storage tank, and the two groups of water baffles are made to move close to or far away from each other by pulling the pull plates;
The top of the liquid storage tank is fixedly provided with a matched gear shell, a driving gear and a reciprocating motor, the driving gear is rotatably arranged in the gear shell and is fixedly connected with a stirring rod, and the stirring rod is rotatably arranged in the liquid storage tank and is positioned between two groups of water baffles;
the two sides of the driving gear are in meshing connection with a toothed plate, one end of the toothed plate is positioned between the gear shell and the driving gear, and the other end of the toothed plate is in sliding connection with a chute block fixed at the top of the liquid storage tank;
the outer wall both sides of liquid storage pot upper half are provided with the fly leaf, fly leaf one end articulates the liquid storage pot outer wall, middle extreme with the arm-tie articulates, the other end with the tooth pattern plate articulates.
Preferably, the constant force polishing control system comprises a polishing force monitoring unit, a polishing position monitoring unit and a total control center;
the polishing force monitoring unit comprises a force sensor and a constant force module, wherein the force sensor is used for monitoring the polishing force in real time and feeding back the polishing force to the constant force module in the polishing process, and the constant force module is used for adjusting and controlling the polishing force to be stable;
the polishing position monitoring unit comprises a position adjusting module, wherein in the polishing process, the distance between the polishing head and the surface of the welding line to be polished is monitored in real time through the laser automatic navigator and fed back to the position adjusting module, and the position adjusting module adjusts and controls the distance between the polishing head and the surface of the welding line to be polished;
The polishing force self-adaptive calculation module is arranged in the total control center, is based on a two-free PID control algorithm, and monitors and adjusts the polishing force of the polishing head in the vertical feeding process by controlling the polishing force and the polishing position, and simultaneously monitors and adjusts the polishing position in the feeding process;
and presetting polishing allowance in the total control center, controlling the polishing force and the polishing position of the polishing head to be circularly monitored and regulated in the vertical feeding process in the polishing process, and carrying out real-time deviation analysis on the distance between the polishing head and the surface of the welding line to be polished and the preset polishing allowance until the deviation analysis result of the distance between the polishing head and the surface of the welding line to be polished and the preset polishing allowance meets an expected value, and terminating polishing execution.
Preferably, the polishing device consists of a sliding table mounting plate, a sliding table, a lifting driving motor, a sliding block, a polishing lifting frame, a suspension spring system, a polishing motor and a polishing head; the suspension spring system consists of a spring and a fixed shaft;
the sliding table mounting plate is connected with the wall climbing travelling mechanism through bolts, the sliding table is connected with the sliding table mounting plate through bolts, the polishing lifting frame is mounted on the sliding block, lifting of the polishing lifting frame is controlled by the lifting driving motor, and downward pressure is transmitted to the polishing head through the suspension spring system;
The polishing motor is fixedly connected to the lower end face of the constant force module, the output end of the polishing motor is connected with a polishing head, the distance between the polishing head and the wall surface of the welding seam is detected in real time through the laser automatic navigator, the detected distance is sent to the control box, and the control box controls the gap between the polishing head and the wall surface of the welding seam through controlling the lifting driving motor.
Preferably, the fixed-point thickness measuring device comprises a sleeve, an electromagnet, a probe mounting seat and a thickness gauge probe, wherein the upper end of the sleeve is fixed on the bottom plate, the electromagnet is arranged in the sleeve, the lower end of a push rod of the electromagnet extends out of the lower end of the sleeve, the lower end of the push rod is connected with the probe mounting seat, and the thickness gauge probe is arranged in the probe mounting seat and is fixed by a set screw.
The invention also provides an operation method of the large-scale pressure equipment weld joint surface and near surface defect repairing and rechecking integrated robot, which comprises the following steps:
s1, marking all defects of a welding line through a magnetic powder detection robot, and then, driving to the marked positions through the wall climbing robot to repair and recheck the defects of the welding line;
s2, the basis of safety assessment on the out-of-standard weld defects is to accurately determine the sizes of the defects;
Performing defect positioning on the weld joint through a wall climbing robot, displaying the length and the shape of the defect, finding out a positioning point of a specific position of the weld joint, performing defect identification on the weld joint defect on a solid, and measuring the defect depth by using a laser automatic navigator 13;
s3, based on the result of defect positioning, firstly, grinding the defect of the weld joint, removing the heat affected zone of the original weld joint, and grinding the defect weld joint;
when centering, the center of the grinding head is completely overlapped with the center line of the determined weld joint needing repairing, the trial running adjustment deviation is adjusted to meet the requirement, the position of the grinding head is adjusted to the position 2mm below the defect of the weld joint by the wall climbing robot 37, the grinding motor is started for grinding, and the grinding stroke is controlled to be 2mm more than the defect position of the weld joint;
after a weld defect is flattened by a flattening polishing head, detecting through a cross magnetic yoke, if a crack exists, marking the weld defect;
s4, removing longitudinal cracks or transverse cracks of the welding seam by adopting a layer-by-layer polishing method;
after all weld defects in the spherical tank are ground by using a grinding and leveling grinding head, quickly moving a wall climbing robot to the bottom of the spherical tank, changing the grinding and leveling grinding head into a pit grinding head, for longitudinal cracks of the weld, adjusting the pit grinding head to be above the longitudinal cracks and parallel to the longitudinal cracks by using the wall climbing robot, moving the pit grinding head to a position 2mm below the weld defects, controlling the pit grinding head to perform local grinding operation, slowly grinding when the defects are removed, measuring the depth by using a laser automatic navigator in the grinding process, and when the grinding amount is 30% of the pit depth, not pressing downwards, rolling forwards for grinding, and controlling the grinding travel to be 2mm more than the position of the weld defects;
S5, detecting through the cross magnetic yoke, if cracks exist, polishing the second layer, wherein the polishing amount of the second layer is 50% of the pit depth respectively, detecting through the cross magnetic yoke after polishing is finished, if cracks exist, polishing the third layer, wherein the polishing amount of the third layer is 70% of the pit depth respectively, detecting through the cross magnetic yoke after polishing is finished, if cracks exist, polishing the fourth layer, and stopping polishing until the polishing amount of the fourth layer is 90% of the pit depth respectively and reaches the maximum value of the determined defect depth;
for the transverse crack of the welding seam, the wall climbing robot rotates ninety degrees, the pit polishing head is adjusted to be above the transverse crack and parallel to the transverse crack, the pit polishing head is moved to a position 2mm outside the welding seam defect, and then the pit polishing head is processed according to the same method;
and S6, performing magnetic powder detection on the residual weld joint through a cross magnetic yoke after the depth of the polished weld joint reaches the maximum value of the determined defect depth, and confirming that the defect of the weld joint is completely removed.
Preferably, the polishing heads are divided into a polishing flat polishing head and a pit polishing head;
the method for checking the strength of the pit formed by the pit polishing head after crack polishing is eliminated, which changes the original stress distribution of the container, cannot simply adopt the residual wall thickness, and can determine whether the pit is in an allowable range by calculating a dimensionless parameter G, wherein the specific judging method is as follows:
(1) Calculating the wall thickness allowance:
the pit depth C of crack formation, if the pit depth C is smaller than the wall thickness allowance (the wall thickness allowance=the measured wall thickness-the nominal thickness+the corrosion allowance), the pit is allowed to exist without repair welding and other modes, otherwise, dimensionless calculation is carried out;
the pit formed after polishing does not need repair welding within an allowable range and does not influence grading; otherwise, repair welding or stress analysis can be performed, and the repair welding qualification or the stress analysis result shows that the safe use is not affected and the repair welding can be performed in two stages or three stages;
the depth of the pit formed after the crack is polished is within the range of the wall thickness allowance, and the pit is allowed to exist. Otherwise, the pit is regularized into a semi-ellipsoidal pit with the length of a long shaft, the length of a short shaft and the depth of 2A (mm), 2B (mm) and C (mm) respectively according to the circumscribed rectangle, and dimensionless parameter G is calculated 0 If G 0 < 0.10, the pit is within the allowable range;
(2) carrying out dimensionless parameters G 0 The calculated pit should satisfy the following condition:
the pit surface is smooth and the transition is gentle, and other surface defects or buried defects do not exist around the pit surface;
the pits are not close to geometrically discontinuous areas or areas where sharp corners exist;
the container is not subjected to external pressure or fatigue load;
A thin-walled cylindrical shell with a T/R less than 0.18 or a thin-walled spherical shell with a T/R less than 0.10;
the material meets the pressure vessel design specifications and no degradation is found;
pit depth C is less than 1/3 and less than 12mm of wall thickness T, pit bottom minimum thickness (T-C) is not less than 3mm;
pit half length
The pit half width B is not less than three times of the pit depth C;
(3) pit defect dimensionless parameter G 0 Is calculated by (1):
wherein T is the wall thickness of the container at the position where the pit is positioned (the measured wall thickness is subtracted by the corrosion amount until the next inspection period, the unit is mm), and R is the average radius of the container (the unit is mm);
before crack polishing is eliminated, a polishing scheme is formulated and pits formed after polishing are calculated, if the precondition of pit evaluation is met and the pits are in an allowable range, polishing is carried out according to the pits, otherwise, polishing is carried out according to a repair welding scheme.
The maximum allowable pit depth Cmax when the dimensionless parameter G is 0.1 is calculated when the pit is polished, the pit depth is smaller than 1/3 of the wall thickness T and smaller than 12mm, the wall thickness of the spherical tank is not smaller than 30mm in general, the maximum allowable pit depth of 10mm can be selected to simultaneously satisfy the pit depth smaller than 1/3 of the wall thickness T and smaller than 12mm, therefore, the pit polishing height h is selected to be 10mm, the maximum polishing depth is 10mm, and the pit half width B is not smaller than 3 times of the pit depth C.
According to the design shape of the pit polishing head, the half width B of the pit is
According to the formula, if C takes 10mm, B is
The pit half length A is not less than the pit half width B, and the pit half length A is
In actual design, R2 is 50mm, and R1 is 100mm in consideration of the fact that the radius of the grinding head is consistent with that of the grinding head, so that key size parameters of the grinding head can be determined, and the pit shape ground by the grinding head completely meets the pit shape and size requirements specified in TSG 21-2016 'fixed pressure vessel safety technical regulations'.
Preferably, in the operation method, a grading polishing technology is adopted, firstly polishing for removing the surplus height of the weld seam is adopted, and a polishing head is adopted for polishing the defect weld seam;
if the defect is not removed after the recheck, polishing according to the maximum pit depth Cmax of the allowable range calculated by the dimensionless parameter G;
the larger the pit depth is, the worse the safety coefficient is, so it is not preferable to directly adopt the maximum allowable pit depth to polish the residual defect, but adopt the pit depth as much as possible to polish the defect, and when the grading polishing design is adopted, whether the smaller maximum pit depth Cmax is larger than 10mm (when the wall thickness is larger than 30mm, if the wall thickness is smaller than 30mm, 1/3 of the wall thickness T is taken), if Cmax is larger than or equal to 10mm, polishing is respectively carried out on 20%, 50%, 70% and 90% of the basis value on the basis of 10mm, if Cmax is smaller than 10mm, polishing is respectively carried out on 20%, 50%, 70% and 90% of the basis value on the basis of Cmax. The grading polishing sequence is as follows: the first time the polishing is performed at 2mm or a maximum allowable pit depth of 20% (taking a smaller value). And then carrying out magnetic powder detection and rechecking, if the defects are not polished, polishing according to the maximum allowable pit depths (respectively taking smaller values) of 5mm, 7mm, 9mm or 50%, 70% and 90% in sequence according to the previous method, and if the defects are not polished yet when polishing according to the maximum allowable pit depths of 90%, manually constructing a scaffold for welding repair.
The pit polishing head is an arc bottom, the width is more than three times of the arc depth h, if Cmax is more than or equal to 10mm, the pit polishing head is used for polishing the formed pit shape and size in a grading way, and the pit shape and size are respectively as follows:
if Cmax is smaller than 10mm, pit shapes and sizes formed by grading polishing of the pit polishing head are respectively as follows:
C 1 :20％ C max mm
B 1 :
A 1 :
C 1 :50％ C max mm
B 1 :
A 1 :
C 1 :70％ C max mm
B 1 :
A 1 :
C 1 :90％ C max mm
B 1 :
A 1 :
and (3) grinding and judging:
the descending distance of the grinding and leveling grinding head is mainly controlled, and if sparks are observed at the corners of the grinding and leveling grinding head, the weld joint can be judged to be leveled;
and (5) pit polishing in-place judgment:
the actual descending distance of the pit polishing head can be known by mainly controlling the descending distance of the pit polishing head and monitoring the pit depth in real time through the laser automatic navigator, and the actual descending distance is fed back to the position adjusting module.
Compared with the prior art, the invention has the beneficial effects that:
the large-scale pressure equipment weld joint surface, near-surface defect repair and reinspection integrated robot performs defect positioning on the weld joint through the traveling wall climbing robot, shows the length and the shape of the defect, measures the defect depth by using a laser navigator, controls a polishing head to perform local polishing operation, measures the depth in the polishing process, realizes polishing and detection integrated operation, and improves the working efficiency.
According to the large-scale pressure-bearing equipment weld joint surface and near-surface defect repairing and rechecking integrated robot, the provided polishing head design aims at the pressure vessel weld joint polishing requirement and the pressure vessel regulation safety requirement, the width of the polishing head is considered for the width of the polishing head, the width and the height of the weld joint are considered, and the stress condition of the weld joint after the residual weld joint is high polished is better; and a grading polishing technology is adopted, firstly polishing for removing the weld seam excess height is adopted, if the defect is not removed after rechecking, the pit depth in the allowable range is calculated according to the calculated dimensionless parameter G specified by TSG 21-2016, and if the defect is not polished off after polishing according to the maximum allowable pit depth of 90%, the manual construction of the scaffold is considered for welding and repairing.
According to the large pressure-bearing equipment weld joint surface and near-surface defect repairing and re-checking integrated robot, magnetic suspension stirring and spraying device can uniformly spray magnetic suspension, and the conventional stepping type cross magnetic yoke technology is adopted in a matched mode, as the pit half length is smaller than the effective magnetization area length of a rotating magnetic field formed by the cross magnetic yoke technology under normal conditions, the pit surface defect can be detected only by one-time magnetization, and the pit half length is larger than the effective magnetization area length of the rotating magnetic field formed by the cross magnetic yoke technology under few conditions, the stepping type sectional cross magnetic yoke technology with more than two times is adopted.
According to the large-scale pressure equipment weld joint surface, near-surface defect repairing and rechecking integrated robot, on one hand, the robot automatically walks along the weld joint to reach a welding defect position, the function is started during polishing and moving and during detecting and moving, on the other hand, the array laser method is adopted to measure geometric dimension parameters of a pit surface, the three-dimensional geometric dimension parameters of the pit surface are obtained in real time through forward walking of the wall climbing robot, although the geometric dimension of the polished pit surface is accurately predicted through polishing depth control of a polishing head, the geometric dimension parameters of the pit can be accurately obtained through laser measurement, and therefore accurate safety assessment of the pit is facilitated.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic diagram of a front view of the overall structure of a robot.
Fig. 2 is a schematic top view of a part of the structure of the robot.
Fig. 3 is a schematic diagram of the front view of the magnetic suspension stirring spraying device.
Fig. 4 is a schematic view of the magnetic suspension stirring sprinkler in front view and in internal cross section.
Fig. 5 is a schematic top view of the toothed plate, gear housing and drive gear.
FIG. 6 is a schematic diagram of a front cross-sectional structure of the fixed-point thickness measuring device.
Fig. 7 is a schematic diagram of the front view of the constant force module, force sensor, grinding motor and grinding head.
Fig. 8 is a schematic diagram showing a front view of a pit grinding head.
Fig. 9 is a schematic view of a construction in which a work robot is located on a spherical tank.
Fig. 10 is a schematic view of a sanding head for sanding different depths on a spherical tank.
Wherein: 1. a mounting plate; 2. a lifting driving motor; 3. a sliding table; 4. a slide block; 5. polishing the lifting frame; 6. a polishing device; 7. a constant force polishing control system; 8. a suspension spring system; 9. a spring; 10. a fixed shaft; 11. a fall arrester; 12. a flange; 13. a laser automatic navigator; 14. a transmission cable; 15. a set screw; 16. a constant force module; 17. a force sensor; 18. polishing a motor; 19. grinding and leveling a grinding head; 20. a mixing system; 2001. a water baffle; 2002. a guide rail; 2003. pulling a plate; 2004. a movable plate; 2005. a toothed plate; 2006. a chute block; 2007. a gear housing; 2008. a drive gear; 2009. a reciprocating motor; 21. a drive shaft mount; 22. a driving motor; 23. a dust-proof partition; 24. a cross yoke; 25. a black light lamp; 26. a spray head; 27. a video detection system; 28. driven wheel; 29. automatically tracking a tripod head; 30. an external operation table; 31. a shielded cable; 32. a fixed-point thickness measuring device; 33. a control box; 34. a bottom plate; 35. a wall climbing travelling mechanism; 36. a magnetic suspension stirring and spraying device; 37. wall climbing robot; 38. a driving wheel; 39. a light source target; 40. pit polishing head; 41. a liquid storage tank; 42. a nozzle; 43. a liquid return pipe; 44. a first water pump; 45. a control device; 46. a liquid suction pipe; 47. a second water pump; 48. an infusion tube; 49. a sleeve; 50. an electromagnet; 51. a probe mounting seat; 52. a thickness gauge probe; 53. a push rod.
Detailed Description
In the description of the present invention, it should be noted that, directions or positional relationships indicated by terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., are directions or positional relationships based on those shown in the drawings, or are directions or positional relationships conventionally put in use of the inventive product, are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the apparatus or elements to be referred to must have a specific direction, be constructed and operated in a specific direction, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," "third," and the like are used merely to distinguish between descriptions and should not be construed as indicating or implying relative importance.
In the description of the present invention, it should also be noted that, unless explicitly specified and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
The present invention will be further described in detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the detailed description and specific examples, while indicating the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. In addition, in the following description, descriptions of well-known structures and techniques are omitted so as not to unnecessarily obscure the present invention.
Example 1:
referring to fig. 1, 2 and 9, an integrated robot for repairing and rechecking defects on the surface and near surface of a weld joint of a large-scale pressure-bearing device comprises a wall climbing robot 37, wherein the wall climbing robot 37 comprises an adsorption module and a wall climbing travelling mechanism 35; the wall climbing travelling mechanism 35 comprises a driving wheel 38, a driven wheel 28, a driving shaft mounting piece 21 and a driving motor 22, and light source targets 39 are arranged on two opposite sides of the wall climbing travelling mechanism 35; the driving shaft mounting piece 21 comprises a driving shaft and a shaft mounting piece, the driving shaft mounting piece 21, the driving motor 22, the driving wheel 38 and the driven wheel 28 are fixedly mounted under the bottom plate 34, and the wall climbing robot 37 can be adsorbed on the inner wall of the spherical tank to walk under the driving of the driving motor 22 through the adsorption module.
When the wall climbing robot 37 works in the spherical tank, the wall climbing robot is connected with the falling protector 11, and the falling protector 11 is fixedly connected to the flange 12 at the top of the spherical tank; an automatic tracking cradle head 29 is arranged at the bottom of the spherical tank, the automatic tracking cradle head 29 is connected with an external operation table 30 through a transmission cable 14, and the external operation table 30 is connected with a control box 33 on a wall climbing robot 37 through a shielding cable 31;
the automatic tracking cradle head 29 is used for monitoring the working condition of the wall climbing robot 37, the external operation table 30 is used for controlling the action of the wall climbing robot 37, and the external operation table 30 comprises display equipment for displaying the detection result of the video detection system 27 and external input equipment for controlling the robot through a singlechip.
Specifically, during the use, will climb wall robot 37 and place on the spherical tank inner wall and adsorb on the spherical tank inner wall, spherical tank top access hole sets up automatic winding drum, connect power cord, the signal line of robot and automatic winding drum are connected, set up the tripod rest in spherical tank bottom entrance, set up automatic tracking cloud platform 29 on the tripod rest, automatic tracking cloud platform 29 can 360 rotations of level and every single move 180 rotations, at any moment, automatic tracking cloud platform 29 will lock the light source target 39 on the robot, automatic tracking cloud platform 29 cable comes out from the bottom manhole and gets into external operation platform 30, automatic winding drum fixed line part cable access is on the external operation platform 30.
A control box 33 and a magnetic suspension stirring and spraying device 36 are fixedly arranged above a bottom plate 34 of the wall climbing robot 37, a cross magnetic yoke 24 is fixedly arranged below the bottom plate 34, a black light lamp 25 and a video detection system 27 are arranged below a cross magnetic yoke 24 iron core beam, and the video detection system 27 comprises a camera and a shooting accessory;
the front of the wall climbing robot 37 is fixedly provided with a polishing device 6 and a constant force polishing control system 7, and the polishing device 6 is fixedly provided with a laser automatic navigator 13;
the laser automatic navigator 13 has two functions, one is to enable a robot to automatically walk along a welding line to reach a welding defect position, the function is started during polishing movement and detecting movement, the other is to measure geometric dimension parameters of a pit surface by adopting an array laser method, three-dimensional geometric dimension parameters of the pit surface are obtained in real time by forward walking of the wall climbing robot 37, although the geometric dimension of the polished pit surface is accurately predicted by polishing depth control of a polishing head, the geometric dimension parameters of the pit can be accurately obtained by laser measurement, and therefore accurate safety assessment of the pit is carried out.
The back of the wall climbing robot 37 is fixedly provided with a fixed-point thickness measuring device 32, and the fixed-point thickness measuring device 32 is mainly used for thickness measurement.
Further, a dust-proof partition 23 is provided between the grinding device 6 and the cross yoke 24, and the dust-proof partition 23 is used for blocking grinding dust.
Example 2:
referring to fig. 1-5, on the basis of the above embodiment, the large-scale pressure-bearing device weld surface and near-surface defect repairing and rechecking integrated robot, the magnetic suspension stirring and spraying device 36 comprises a stirring device, a liquid storage tank 41, a spraying device and a control device 45;
the bottom surface of the liquid storage tank 41 is fixedly communicated with a liquid suction pipe 46, the liquid suction pipe 46 is respectively communicated with a stirring device and a spraying device, and the stirring device and the spraying device are respectively electrically connected with a control device 45; the stirring device is used for stirring the magnetic suspension of the liquid storage tank 41, the spraying device is used for spraying the magnetic suspension, and the control device 45 is used for respectively controlling the starting and stopping of the stirring device and the spraying device;
the stirring device comprises a first water pump 44, a nozzle 42 and a liquid return pipe 43;
the first water pump 44 and the nozzle 42 are communicated with the bottom surface of the liquid storage tank 41 through the liquid return pipe 43 and the liquid suction pipe 46, the first water pump 44 is electrically connected with the control device 45, the first water pump 44 pumps out the magnetic suspension with high concentration from the bottom of the liquid storage tank 41 and discharges the magnetic suspension through the nozzle 42, the nozzle 42 is arranged in the liquid storage tank 41, and the spraying direction of the nozzle 42 is parallel to the bottom surface of the liquid storage tank 41 and tangential to the vertical surface of the liquid storage tank 41 so as to enhance the mixing effect;
The spraying device comprises a second water pump 47, a transfusion tube 48 and a spray head 26;
the second water pump 47 and the spray head 26 are communicated with the bottom surface of the liquid storage tank 41 through a liquid conveying pipe 48 and a liquid sucking pipe 46, the second water pump 47 is electrically connected with the control device 45, and the second water pump 47 sucks out the mixed magnetic suspension from the liquid storage tank 41 and discharges the mixed magnetic suspension through the spray head 26.
Specifically, when the stirring device is controlled by the control device 45 to stir, the first water pump 44 pumps out the magnetic suspension with larger concentration from the bottom of the liquid storage tank 41 through the liquid pumping pipe 46, forms high-speed jet flow from the nozzle 42 through the liquid return pipe 43 and sprays the high-speed jet flow back into the liquid storage tank 41, and under the action of the high-speed jet flow and the wall surface of the liquid storage tank 41, the magnetic suspension at the bottom end part in the liquid storage tank 41 flows fast, and the magnetic suspension with larger concentration is automatically stirred and mixed; and the second water pump 47 pumps the mixed magnetic suspension from the reservoir 41 and discharges it through the spray head 26.
Further, the mixing system 20 is further arranged inside and outside the liquid storage tank 41, the mixing system 20 comprises two groups of water baffles 2001 arranged inside the liquid storage tank 41, the water baffles 2001 are slidably connected to the upper half part of the liquid storage tank 41 through guide rails 2002, a pull plate 2003 is fixedly connected to one side of each water baffle 2001, each pull plate 2003 penetrates through the corresponding water baffle 2001 and extends to the outside of the liquid storage tank 41, and the two groups of water baffles 2001 are moved to be close to or far away from each other by pulling the pull plate 2003;
The top of the liquid storage tank 41 is fixedly provided with a matched gear shell 2007, a driving gear 2008 and a reciprocating motor 2009, the driving gear 2008 is rotatably arranged in the gear shell 2007, and is fixedly connected with a stirring rod which is rotatably arranged in the liquid storage tank 41 and is positioned between two groups of water baffles 2001;
the two sides of the driving gear 2008 are in meshing connection with a toothed plate 2005, one end of the toothed plate 2005 is positioned between the gear housing 2007 and the driving gear 2008, and the other end of the toothed plate 2005 is in sliding connection with a chute block 2006 fixed at the top of the liquid storage tank 41;
the two sides of the outer wall of the upper half part of the liquid storage tank 41 are provided with movable plates 2004, one end of each movable plate 2004 is hinged to the outer wall of the liquid storage tank 41, the middle end of each movable plate 2004 is hinged to the corresponding pull plate 2003, and the other end of each movable plate 2004 is hinged to the corresponding toothed plate 2005.
Specifically, when the magnetic suspension at the bottom end part in the liquid storage tank 41 flows and mixes rapidly, the reciprocating motor 2009 is started to drive the driving gear 2008 and the stirring rod to stir at the upper half part in the liquid storage tank 41, and simultaneously the toothed plate 2005 is driven by the driving gear 2008 to reciprocate forward and backward to move left and right, so that the movable plate 2004 is driven to reciprocate left and right, and as the water baffles 2001 are connected to the upper half part of the liquid storage tank 41 in a sliding manner through the guide rails 2002, the two groups of water baffles 2001 move close to each other or away from each other, so that the magnetic suspension at the upper half part of the liquid storage tank 41 is continuously extruded downwards and then diffused again, and the magnetic suspension in the liquid storage tank 41 flows completely, so that the condition of uneven concentration of the magnetic suspension during spraying is avoided.
The scheme in this embodiment may be selectively used in combination with the scheme in other embodiments.
Example 3:
referring to fig. 1, 7 and 8, based on the above embodiments, the large-scale pressure-bearing device weld surface and near-surface defect repairing and rechecking integrated robot, the constant force polishing control system 7 comprises a polishing force monitoring unit, a polishing position monitoring unit and a total control center;
the polishing force monitoring unit comprises a force sensor 17 and a constant force module 16, wherein in the polishing process, the force sensor 17 is used for monitoring the polishing force in real time and feeding back to the constant force module 16, and the constant force module 16 is used for adjusting and controlling the polishing force to be stable;
the polishing position monitoring unit comprises a position adjusting module, and in the polishing process, the distance between the polishing head and the surface of the welding line to be polished is monitored in real time through the laser automatic navigator 13 and fed back to the position adjusting module, and the position adjusting module adjusts and controls the distance between the polishing head and the surface of the welding line to be polished;
the polishing force self-adaptive calculation module is arranged in the total control center, is based on a two-free PID control algorithm, and realizes the monitoring and adjustment of the polishing force in the vertical feeding process of the polishing head and the monitoring and adjustment of the polishing position in the feeding process by controlling the polishing force and the polishing position;
The polishing allowance is preset in the total control center, in the polishing process, the polishing force and the polishing position of the polishing head are controlled to be circularly monitored and adjusted in the vertical feeding process, real-time deviation analysis is carried out on the distance between the polishing head and the surface of the welding line to be polished and the preset polishing allowance until the deviation analysis result of the distance between the polishing head and the surface of the welding line to be polished and the preset polishing allowance meets the expected value, and polishing execution is terminated.
The polishing device 6 consists of a sliding table mounting plate 1, a sliding table 3, a lifting driving motor 2, a sliding block 4, a polishing lifting frame 5, a suspension spring system 8, a polishing motor 18 and a polishing head; the suspension spring system 8 consists of a spring 9 and a fixed shaft 10;
the sliding table mounting plate 1 is connected with the wall climbing travelling mechanism 35 through bolts, the sliding table 3 is connected with the sliding table mounting plate 1 through bolts, the polishing lifting frame 5 is mounted on the sliding block 4, the lifting of the polishing lifting frame 5 is controlled by the lifting driving motor 2, and the downward pressure is transmitted to the polishing head through the suspension spring system 8;
the polishing motor 18 is fixedly connected to the lower end face of the constant force module 16, the output end of the polishing motor 18 is connected with a polishing head, the distance between the polishing head and the wall surface of the welding seam is detected in real time through the laser automatic navigator 13, the detected distance is sent to the control box 33, and the control box 33 controls the gap between the polishing head and the wall surface of the welding seam by controlling the lifting driving motor 2.
Specifically, when the polishing device is used, the lifting driving motor 2 is used for controlling the lifting of the polishing lifting frame 5, so that the spring 9 and the fixed shaft 10 downwards move to transmit the downward pressure to the polishing head, and the polishing motor 18 is used for driving the polishing head to polish; meanwhile, the distance between the polishing head and the wall surface of the welding seam is detected in real time through the laser automatic navigator 13, the detected distance is sent to the control box 33, and the control box 33 controls the gap between the polishing head and the wall surface of the welding seam by controlling the lifting driving motor 2.
The scheme in this embodiment may be selectively used in combination with the scheme in other embodiments.
Example 4:
referring to fig. 1 and 6, based on the above embodiment, the robot for repairing and checking defects on the weld surface and near surface of a large-scale pressure-bearing device includes a sleeve 49, an electromagnet 50, a probe mount 51 and a thickness gauge probe 52, wherein the upper end of the sleeve 49 is fixed on a bottom plate 34, the electromagnet 50 is mounted in the sleeve 49, the lower end of a push rod 53 of the electromagnet 50 extends out from the lower end of the sleeve 49, the lower end of the push rod 53 is connected with the probe mount 51, and the thickness gauge probe 52 is mounted in the probe mount 51 and is fixed by a set screw 15.
Specifically, when the electromagnet 50 is electrified, the probe 52 of the thickness gauge and the probe mounting seat 51 move downwards to contact the metal working surface together for thickness measurement; when the electromagnet 50 is powered off, the probe 52 of the thickness gauge and the probe mounting seat 51 are restored upwards together.
The scheme in this embodiment may be selectively used in combination with the scheme in other embodiments.
Example 5:
referring to fig. 1 to 10, on the basis of the foregoing embodiment, the embodiment of the present invention further provides an operation method of an integrated robot for repairing and rechecking defects on a weld surface and a near surface of a large-scale pressure-bearing device, which specifically includes the following steps:
s1, marking all defects of a welding line through a magnetic powder detection robot, and then driving to the marked positions through the wall climbing robot 37 to repair and recheck the defects of the welding line;
s2, the basis of safety assessment on the out-of-standard weld defects is to accurately determine the sizes of the defects;
performing defect positioning on the weld joint through a wall climbing robot, displaying the length and the shape of the defect, finding out a positioning point of a specific position of the weld joint, performing defect identification on the weld joint defect on a solid, and measuring the defect depth by using a laser automatic navigator 13;
For short defects of welding seams, the cross magnet yoke 24 moves to the polished defect position during magnetic powder detection, and the detection is performed in a fixed mode; for the long defect of the welding line, the cross magnet yoke 24 moves to the position of the lowest defect after polishing during magnetic powder detection, and the welding line is fixed for detection; then, the device advances for a certain distance and is fixed for detection; the sectional stepping detection mode is realized.
S3, based on the result of defect mark positioning, firstly, grinding the defect of the weld joint, removing the heat affected zone of the original weld joint, and grinding the defect weld joint;
when in centering, the center of the grinding and leveling grinding head 19 is completely coincident with the center line of the determined weld joint needing repairing, the trial running adjustment deviation is adjusted to meet the requirement, the wall climbing robot 37 is used for adjusting the position of the grinding and leveling grinding head 19 to the position 2mm below the defect of the weld joint, the grinding motor 18 is started for grinding, and the grinding stroke is controlled to be 2mm more than the defect position of the weld joint;
after a weld defect is flattened by a flattening polishing head 19, detecting through a cross yoke 24, if a crack exists, firstly marking the position;
s4, removing longitudinal cracks or transverse cracks of the welding seam by adopting a layer-by-layer polishing method;
after all weld defects in the spherical tank are ground by using a grinding and leveling grinding head 19, quickly moving a wall climbing robot 37 to the bottom of the spherical tank, replacing the grinding and leveling grinding head 19 with a pit grinding head 40, for longitudinal cracks of the weld, adjusting the pit grinding head 40 to be above the longitudinal cracks and parallel to the longitudinal cracks by using the wall climbing robot 37, moving the pit grinding head 40 to a position 2mm below the weld defects, operating the pit grinding head 40 to perform local grinding operation, slowly grinding when the defects are removed, measuring the depth by using the wall climbing robot 37 by using a laser automatic navigator 13 in the grinding process, and when the grinding amount is 30% of the pit depth, not pressing downwards, rolling forward for grinding, and controlling the grinding travel to be 2mm more than the position of the weld defects;
S5, detecting through the cross magnet yoke 24, if cracks exist, polishing the second layer, wherein the polishing amount of the second layer is 50% of the pit depth respectively, detecting through the cross magnet yoke 24 after polishing is finished, if cracks exist, polishing the third layer, wherein the polishing amount of the third layer is 70% of the pit depth respectively, detecting through the cross magnet yoke 24 after polishing is finished, if cracks exist, polishing the fourth layer, and polishing the fourth layer until the polishing amount of the fourth layer is 90% of the pit depth respectively, and stopping polishing until polishing reaches the maximum value of the determined defect depth;
for the transverse crack of the weld joint, the wall climbing robot 37 rotates ninety degrees, adjusts the pit polishing head 40 to be above the transverse crack and parallel to the transverse crack, and the pit polishing head 40 moves to a position 2mm outside the weld joint defect and then carries out treatment according to the same method;
and S6, after the depth of the polished weld reaches the maximum value of the determined defect depth, carrying out magnetic powder detection on the residual weld through the cross magnet yoke 24, and confirming that the defect of the weld is completely removed.
It should be noted that, pit portion wall thickness checking calculation: after determining that the pit is allowed to exist, determining whether the wall thickness of the pit bottom meets the requirement of the strength of the spherical tank or not in order to ensure the safe operation of the spherical tank; and checking the wall thickness strength of the pit part, and if the minimum calculation requirement cannot be met, checking the spherical shell wall stress of the pit part. And the magnetic powder detection robot marking (marking) technology adopts the existing information technology, and detailed description is omitted here.
Specifically, when in use, after the wall climbing robot marks and locates all defects of the welding line, the repairing procedure of the welding line defects is as follows: firstly, treating the lower weld defects, then treating the upper weld defects, grinding one weld defect by a grinding and flattening grinding head 19, detecting through a cross magnetic yoke 24 if cracks exist, and marking the position; if the welding line defect exists in other places in the spherical tank, the grinding head 19 is not replaced, the wall climbing robot 37 is operated to the next welding line defect, the welding line defect is ground by the grinding head 19, the welding line defect is detected through the crossed magnetic yoke 24, if the welding line defect exists, the welding line defect is marked; until all weld defects in the spherical tank are ground, the wall climbing robot 37 rapidly moves to the bottom of the spherical tank, the pit grinding head 40 is used for replacing the grinding head 19, and then the marked crack defects are ground and detected layer by layer.
The scheme in this embodiment may be selectively used in combination with the scheme in other embodiments.
Example 6:
referring to fig. 1 to 10, on the basis of the foregoing embodiment, the embodiment of the present invention further provides an operation method of an integrated robot for repairing and rechecking defects on a weld surface and a near surface of a large-scale pressure-bearing device, where polishing heads are divided into a polishing head 19 and a pit polishing head 40;
In the method, for the pit formed by the pit polishing head 40 after the crack polishing is eliminated, the original stress distribution of the container is changed, so that the method of checking the strength by the residual wall thickness cannot be simply adopted, and whether the pit is within the allowable range is determined by calculating the dimensionless parameter G, which is specifically determined as follows:
(1) calculating the wall thickness allowance:
the pit depth C of crack formation, if the pit depth C is smaller than the wall thickness allowance (the wall thickness allowance=the measured wall thickness-the nominal thickness+the corrosion allowance), the pit is allowed to exist without repair welding and other modes, otherwise, dimensionless calculation is carried out;
the pit formed after polishing does not need repair welding within an allowable range and does not influence grading; otherwise, repair welding or stress analysis can be performed, and the repair welding qualification or the stress analysis result shows that the safe use is not affected and the repair welding can be performed in two stages or three stages;
the depth of the pit formed after the crack is polished is within the range of the wall thickness allowance, and the pit is allowed to exist. Otherwise, the pit is regularized into a semi-ellipsoidal pit with the length of a long shaft, the length of a short shaft and the depth of 2A (mm), 2B (mm) and C (mm) respectively according to the circumscribed rectangle, and dimensionless parameter G is calculated 0 If G 0 < 0.10, the pit is within the allowable range;
(2) Carrying out dimensionless parameters G 0 The calculated pit should satisfy the following condition:
the pit surface is smooth and the transition is gentle, and other surface defects or buried defects do not exist around the pit surface;
the pits are not close to geometrically discontinuous areas or areas where sharp corners exist;
the container is not subjected to external pressure or fatigue load;
a thin-walled cylindrical shell with a T/R less than 0.18 or a thin-walled spherical shell with a T/R less than 0.10;
the material meets the pressure vessel design specifications and no degradation is found;
pit depth C is less than 1/3 and less than 12mm of wall thickness T, pit bottom minimum thickness (T-C) is not less than 3mm;
pit half length
The pit half width B is not less than three times of the pit depth C;
(3) pit defect dimensionless parameter G 0 Is calculated by (1):
wherein T is the wall thickness of the container at the position where the pit is positioned (the measured wall thickness is subtracted by the corrosion amount until the next inspection period, the unit is mm), and R is the average radius of the container (the unit is mm);
before crack polishing is eliminated, a polishing scheme is formulated and pits formed after polishing are calculated, if the precondition of pit evaluation is met and the pits are in an allowable range, polishing is carried out according to the pits, otherwise, polishing is carried out according to a repair welding scheme.
The maximum allowable pit depth Cmax when the dimensionless parameter G is 0.1 is calculated when the pit is polished, the pit depth is smaller than 1/3 of the wall thickness T and smaller than 12mm, the wall thickness of the spherical tank is not smaller than 30mm in general, the maximum allowable pit depth of 10mm can be selected to simultaneously satisfy the pit depth smaller than 1/3 of the wall thickness T and smaller than 12mm, therefore, the pit polishing height h is selected to be 10mm, the maximum polishing depth is 10mm, and the pit half width B is not smaller than 3 times of the pit depth C.
According to the design shape of the pit polishing head, the half width B of the pit is
According to the formula, if C takes 10mm, B is
The pit half length A is not less than the pit half width B, and the pit half length A is
In actual design, R2 is 50mm, and R1 is 100mm in consideration of the fact that the radius of the grinding head is consistent with that of the grinding head, so that key size parameters of the grinding head can be determined, and the pit shape ground by the grinding head completely meets the pit shape and size requirements specified in TSG 21-2016 'fixed pressure vessel safety technical regulations'.
Further, in the above operation method, a grading polishing technology is adopted, firstly polishing for removing the surplus height of the weld seam is adopted, and a polishing head 19 is adopted for polishing the defective weld seam;
if the defect is not removed after the recheck, polishing according to the maximum pit depth Cmax of the allowable range calculated by the dimensionless parameter G;
the larger the pit depth is, the worse the safety coefficient is, so it is not preferable to directly adopt the maximum allowable pit depth to polish the residual defect, but adopt the pit depth as much as possible to polish the defect, and when the grading polishing design is adopted, whether the smaller maximum pit depth Cmax is larger than 10mm (when the wall thickness is larger than 30mm, if the wall thickness is smaller than 30mm, 1/3 of the wall thickness T is taken), if Cmax is larger than or equal to 10mm, polishing is respectively carried out on 20%, 50%, 70% and 90% of the basis value on the basis of 10mm, if Cmax is smaller than 10mm, polishing is respectively carried out on 20%, 50%, 70% and 90% of the basis value on the basis of Cmax. The grading polishing sequence is as follows: the first time the polishing is performed at 2mm or a maximum allowable pit depth of 20% (taking a smaller value). And then carrying out magnetic powder detection and rechecking, if the defects are not polished, polishing according to the maximum allowable pit depths (respectively taking smaller values) of 5mm, 7mm, 9mm or 50%, 70% and 90% in sequence according to the previous method, and if the defects are not polished yet when polishing according to the maximum allowable pit depths of 90%, manually constructing a scaffold for welding repair.
The pit polishing head 40 is an arc bottom, the width is more than 3 times of the arc depth h, for example, cmax is more than or equal to 10mm, and the pit shape and the size formed by grading polishing of the pit polishing head 40 are respectively as follows:
if Cmax is smaller than 10mm, pit polishing heads (40) polish in grades to form pit shapes with the following sizes:
C 1 :20％ C max mm
B 1 :
A 1 :
C 1 :50％ C max mm
B 1 :
A 1 :
C 1 :70％ C max mm
B 1 :
A 1 :
C 1 :90％ C max mm
B 1 :
A 1 :
and (3) grinding and judging:
the descending distance of the grinding and leveling grinding head 19 is mainly controlled, and in addition, if sparks are observed at the corners of the grinding and leveling grinding head 19, the fact that the welding line is ground is also judged;
and (5) pit polishing in-place judgment:
the actual descending distance of the pit polishing head 40 can be known and fed back to the position adjusting module by mainly controlling the descending distance of the pit polishing head 40 and monitoring the pit depth in real time through the laser automatic navigator 13.
The scheme in this embodiment may be selectively used in combination with the scheme in other embodiments.
It should be noted that, although the foregoing embodiments have been described herein, the scope of the present invention is not limited thereby. Therefore, based on the innovative concepts of the present invention, alterations and modifications to the embodiments described herein, or equivalent structures, equivalent flows or equivalent functional transformations made by the present description and drawings, apply the above technical solutions directly or indirectly to other relevant technical fields, all of which are included in the scope of protection of the present patent.
Claims (10)
1. The utility model provides a large-scale pressure equipment welding seam surface, nearly surface defect repair and reinspection integration robot, includes wall climbing robot (37), its characterized in that: the wall climbing robot (37) comprises an adsorption module and a wall climbing travelling mechanism (35);
a control box (33) and a magnetic suspension stirring and spraying device (36) are fixedly arranged above a bottom plate (34) of the wall climbing robot (37), a cross magnetic yoke (24) is fixedly arranged below the bottom plate (34), and a black light lamp (25) and a video detection system (27) are arranged below an iron core beam of the cross magnetic yoke (24);
a polishing device (6) and a constant force polishing control system (7) are fixedly arranged in front of the wall climbing robot (37), and a laser automatic navigator (13) is fixedly arranged on the polishing device (6);
a fixed-point thickness measuring device (32) is fixedly arranged at the rear part of the wall climbing robot (37);
a dustproof clapboard (23) is arranged between the polishing device (6) and the cross magnetic yoke (24);
when the wall climbing robot (37) works in the spherical tank, the wall climbing robot is connected with a falling protector (11), and the falling protector (11) is fixedly connected to a flange (12) at the top of the spherical tank;
the automatic tracking cloud deck (29) is arranged at the bottom of the spherical tank, the automatic tracking cloud deck (29) is connected with an external operation table (30) through a transmission cable (14), and the external operation table (30) is connected with a control box (33) on a wall climbing robot (37) through a shielding cable (31).
2. The integrated robot for repairing and rechecking defects on the surface and near surface of a weld joint of large-scale pressure equipment according to claim 1, wherein the integrated robot is characterized in that: the wall climbing travelling mechanism (35) comprises a driving wheel (38), a driven wheel (28), a driving shaft mounting piece (21) and a driving motor (22), and light source targets (39) are arranged on two opposite sides of the wall climbing travelling mechanism (35).
3. The integrated robot for repairing and rechecking defects on the surface and near surface of a weld joint of large-scale pressure equipment according to claim 1, wherein the integrated robot is characterized in that: the magnetic suspension stirring and spraying device (36) comprises a stirring device, a liquid storage tank (41), a spraying device and a control device (45);
the bottom surface of the liquid storage tank (41) is fixedly communicated with a liquid suction pipe (46), the liquid suction pipe (46) is respectively communicated with a stirring device and a spraying device, and the stirring device and the spraying device are respectively electrically connected with a control device (45);
the stirring device comprises a first water pump (44), a nozzle (42) and a liquid return pipe (43);
the first water pump (44), the nozzle (42) and the bottom surface of the liquid storage tank (41) are communicated through the liquid return pipe (43) and the liquid suction pipe (46), the first water pump (44) is electrically connected with the control device (45), the first water pump (44) is used for sucking the magnetic suspension with high concentration from the bottom of the liquid storage tank (41) and discharging the magnetic suspension through the nozzle (42), and the nozzle (42) is arranged in the liquid storage tank (41) and the spraying direction of the nozzle is parallel to the bottom surface of the liquid storage tank (41);
The spraying device comprises a second water pump (47), a transfusion tube (48) and a spray head (26);
the second water pump (47), the spray head (26) and the bottom surface of the liquid storage tank (41) are communicated through the infusion tube (48) and the liquid suction tube (46), the second water pump (47) is electrically connected with the control device (45), and the mixed magnetic suspension is pumped out of the liquid storage tank (41) by the second water pump (47) and is discharged through the spray head (26).
4. A large scale pressure equipment weld surface, near surface defect repair and reinspection integrated robot according to claim 3, wherein: the mixing system (20) is further arranged inside and outside the liquid storage tank (41), the mixing system (20) comprises two groups of water baffles (2001) arranged inside the liquid storage tank (41), the water baffles (2001) are slidably connected to the upper half part of the liquid storage tank (41) through guide rails (2002), a pull plate (2003) is fixedly connected to one side of each water baffle (2001), each pull plate (2003) penetrates through the corresponding water baffles (2001) and extends to the outside of the liquid storage tank (41), and the two groups of water baffles (2001) are made to move close to or away from each other by pulling the pull plate (2003);
the top of the liquid storage tank (41) is fixedly provided with a matched gear housing (2007), a driving gear (2008) and a reciprocating motor (2009), the driving gear (2008) is rotatably arranged in the gear housing (2007), and is fixedly connected with a stirring rod which is rotatably arranged in the liquid storage tank (41) and is positioned between two groups of water baffles (2001);
Two sides of the driving gear (2008) are in meshing connection with a toothed plate (2005), one end of the toothed plate (2005) is positioned between the gear housing (2007) and the driving gear (2008), and the other end of the toothed plate is in sliding connection with a chute block (2006) fixed at the top of the liquid storage tank (41);
two sides of the outer wall of the upper half part of the liquid storage tank (41) are provided with movable plates (2004), one end of each movable plate (2004) is hinged to the outer wall of the liquid storage tank (41), the middle end of each movable plate is hinged to the corresponding pulling plate (2003), and the other end of each movable plate is hinged to the corresponding toothed plate (2005).
5. The integrated robot for repairing and rechecking defects on the surface and near surface of a weld joint of large-scale pressure equipment according to claim 1, wherein the integrated robot is characterized in that: the constant force polishing control system (7) comprises a polishing force monitoring unit, a polishing position monitoring unit and a total control center;
the polishing force monitoring unit comprises a force sensor (17) and a constant force module (16), wherein in the polishing process, the force sensor (17) is used for monitoring the polishing force in real time and feeding back to the constant force module (16), and the constant force module (16) is used for adjusting and controlling the polishing force to be stable;
the polishing position monitoring unit comprises a position adjusting module, wherein in the polishing process, the distance between the polishing head and the surface of the welding line to be polished is monitored in real time through a laser automatic navigator (13) and fed back to the position adjusting module, and the position adjusting module adjusts and controls the distance between the polishing head and the surface of the welding line to be polished;
The polishing force self-adaptive calculation module is arranged in the total control center, is based on a two-free PID control algorithm, and monitors and adjusts polishing force of the polishing head in the vertical feeding process by controlling the polishing force and the polishing position, and simultaneously monitors and adjusts the polishing position in the feeding process.
6. The integrated robot for repairing and rechecking defects on the surface and near surface of a weld joint of large-scale pressure equipment according to claim 5, wherein the integrated robot is characterized in that: the polishing device (6) consists of a sliding table mounting plate (1), a sliding table (3), a lifting driving motor (2), a sliding block (4), a polishing lifting frame (5), a suspension spring system (8), a polishing motor (18) and a polishing head; the suspension spring system (8) consists of a spring (9) and a fixed shaft (10);
the sliding table mounting plate (1) is connected with the wall climbing travelling mechanism (35) through bolts, the sliding table (3) is connected with the sliding table mounting plate (1) through bolts, the polishing lifting frame (5) is mounted on the sliding block (4), lifting of the polishing lifting frame (5) is controlled by the lifting driving motor (2), and downward pressure is transmitted to the polishing head through the suspension spring system (8);
the polishing motor (18) is fixedly connected to the lower end face of the constant force module (16), the output end of the polishing motor (18) is connected with a polishing head, the distance between the polishing head and the wall surface of the welding seam is detected in real time through the laser automatic navigator (13) and is sent to the control box (33), and the control box (33) controls the gap between the polishing head and the wall surface of the welding seam by controlling the lifting driving motor (2).
7. The integrated robot for repairing and rechecking defects on the surface and near surface of a weld joint of large-scale pressure equipment according to claim 1, wherein the integrated robot is characterized in that: fixed point thickness measuring device (32) include sleeve (49), electro-magnet (50), probe mount pad (51) and thickness gauge probe (52), the upper end of sleeve (49) is fixed on bottom plate (34), electro-magnet (50) are installed in sleeve (49), push rod (53) lower extreme of electro-magnet (50) is stretched out by the lower extreme of sleeve (49), push rod (53) lower extreme is connected with probe mount pad (51), thickness gauge probe (52) are installed in probe mount pad (51) and are fixed with holding screw (15).
8. The operation method of the large pressure equipment weld joint surface and near surface defect repairing and rechecking integrated robot is characterized by comprising the following steps:
s1, marking all defects of a welding line through a magnetic powder detection robot, and then driving to the marked positions through the wall climbing robot (37) to repair and recheck the defects of the welding line;
s2, the basis of safety assessment on the out-of-standard weld defects is to accurately determine the sizes of the defects;
performing defect positioning on the weld joint through a wall climbing robot, displaying the length and the shape of the defect, finding out a positioning point of a specific position of the weld joint, performing defect identification on the weld joint defect on a solid, and measuring the defect depth by using a laser automatic navigator (13);
S3, based on the result of defect positioning, firstly, grinding the defect of the weld joint, removing the heat affected zone of the original weld joint, and grinding the defect weld joint;
when in centering, the center of the grinding and leveling grinding head (19) is completely coincident with the center line of the determined weld joint needing repairing, the trial running adjustment deviation is adjusted to meet the requirement, the wall climbing robot (37) is used for adjusting the position of the grinding and leveling grinding head (19) to the position 2mm below the defect of the weld joint, the grinding motor (18) is started for grinding, and the grinding stroke is controlled to be 2mm more than the defect position of the weld joint;
after a weld defect is flattened by a flattening polishing head (19), detecting through a cross magnetic yoke (24), if cracks exist, marking the weld defect;
s4, removing longitudinal cracks or transverse cracks of the welding seam by adopting a layer-by-layer polishing method;
after all weld defects in the spherical tank are ground by using a grinding and leveling grinding head (19), quickly moving a wall climbing robot (37) to the bottom of the spherical tank, changing the grinding and leveling grinding head (19) into a pit grinding head (40), for longitudinal cracks of the weld, adjusting the pit grinding head (40) to be above the longitudinal cracks and parallel to the longitudinal cracks by using the wall climbing robot (37), moving the pit grinding head (40) to a position 2mm below the weld defects, controlling the pit grinding head (40) to perform local grinding operation, slowly grinding during defect removal, measuring the depth by using the wall climbing robot (37) by using a laser automatic navigator (13), and when the grinding amount is 30% of the depth of the pit, not pressing downwards, rolling forwards for grinding, and controlling the grinding stroke to be 2mm more than the position of the weld defects;
S5, detecting through the crossed magnetic yoke (24), if cracks exist, polishing the second layer, wherein the polishing amount of the second layer is 50% of the pit depth respectively, detecting through the crossed magnetic yoke (24) after polishing is finished, if cracks exist, polishing the third layer, wherein the polishing amount of the third layer is 70% of the pit depth respectively, detecting through the crossed magnetic yoke (24) after polishing is finished, if cracks exist, polishing the fourth layer, and until polishing is finished to the maximum value of the determined defect depth, stopping polishing;
for transverse cracks of the welding line, the wall climbing robot (37) rotates ninety degrees, the pit polishing head (40) is adjusted to be above the transverse cracks and parallel to the transverse cracks, the pit polishing head (40) is moved to a position 2mm outside the welding line defect, and then the welding line defect is treated according to the same method;
and S6, after the polished weld joint depth reaches the maximum value of the determined defect depth, carrying out magnetic powder detection on the residual weld joint through a cross magnetic yoke (24), and confirming that the weld joint defects are completely removed.
9. The method for operating the integrated robot for repairing and rechecking the defects on the surface and near surface of the welding seam of the large-scale pressure-bearing equipment according to claim 8, which is characterized in that: the polishing heads are divided into a polishing flat polishing head (19) and a pit polishing head (40);
Wherein, for the pit formed by the pit polishing head (40) after crack polishing is eliminated, the original stress distribution of the container is changed, so that the method of checking the strength by the residual wall thickness cannot be simply adopted, and whether the pit is in the allowable range or not is determined by calculating the dimensionless parameter G, and the specific judging method is as follows:
(1) calculating the wall thickness allowance:
the pit depth C formed by the crack is smaller than the wall thickness allowance, so that the pit is allowed to be processed without repair welding or other modes, otherwise, dimensionless calculation is carried out;
the pit formed after polishing does not need repair welding within an allowable range and does not influence grading; otherwise, repair welding or stress analysis can be performed, and the repair welding qualification or the stress analysis result shows that the safe use is not affected and the repair welding can be performed in two stages or three stages;
the depth of the pit formed after the crack is polished is within the range of the wall thickness allowance, and the pit is allowed to exist. Otherwise, the pit is regularized into a semi-ellipsoidal pit with the length of a long shaft, the length of a short shaft and the depth of 2A, 2B and C respectively according to the circumscribed rectangle, and a dimensionless parameter G is calculated 0 If G 0 < 0.10, the pit is within the allowable range;
(2) carrying out dimensionless parameters G 0 The calculated pit should satisfy the following condition:
the pit surface is smooth and the transition is gentle, and other surface defects or buried defects do not exist around the pit surface;
the pits are not close to geometrically discontinuous areas or areas where sharp corners exist;
the container is not subjected to external pressure or fatigue load;
a thin-walled cylindrical shell with a T/R less than 0.18 or a thin-walled spherical shell with a T/R less than 0.10;
the material meets the pressure vessel design specifications and no degradation is found;
pit depth C is less than 1/3 and less than 12mm of wall thickness T, pit bottom minimum thickness (T-C) is not less than 3mm;
pit half length
The pit half width B is not less than three times of the pit depth C;
(3) pit defectsDimensionless parameter G 0 Is calculated by (1):
wherein T is the wall thickness of the container at the position where the pit is positioned, the measured wall thickness is subtracted to the corrosion amount in the next inspection period, and R is the average radius of the container;
before crack polishing is eliminated, a polishing scheme is formulated and pits formed after polishing are calculated, if the precondition of pit evaluation is met and the pits are in an allowable range, polishing is carried out according to the pits, otherwise, polishing is carried out according to a repair welding scheme.
The maximum allowable pit depth Cmax when the dimensionless parameter G is 0.1 is calculated when the pit is polished, the pit depth is smaller than 1/3 of the wall thickness T and smaller than 12mm, the wall thickness of the spherical tank is not smaller than 30mm in general, the maximum allowable pit depth of 10mm can be selected to simultaneously satisfy the pit depth smaller than 1/3 of the wall thickness T and smaller than 12mm, therefore, the pit polishing height h is selected to be 10mm, the maximum polishing depth is 10mm, and the pit half width B is not smaller than 3 times of the pit depth C.
According to the design shape of the pit polishing head, the half width B of the pit is
According to the formula, if C takes 10mm, B is
The pit half length A is not less than the pit half width B, and the pit half length A is
10. The method for operating the integrated robot for repairing and rechecking the defects on the surface and near surface of the welding seam of the large-scale pressure-bearing equipment according to claim 9, which is characterized in that: in the operation method, a grading polishing technology is adopted, firstly, polishing for removing the surplus height of the weld joint is adopted, and a polishing head (19) is adopted for polishing the defective weld joint;
if the defect is not removed after the recheck, polishing according to the maximum pit depth Cmax of the allowable range calculated by the dimensionless parameter G;
the larger the pit depth is, the worse the safety coefficient is, so that the residual defects are not directly polished by adopting the maximum allowable pit depth, but the defects are polished by adopting the pit depth as far as possible, and when the pit depth is larger than or equal to 10mm, the smaller maximum pit depth Cmax which is compared firstly is used for grading polishing design, if Cmax is larger than or equal to 10mm, the base values of 10mm are respectively used for polishing, and if Cmax is smaller than 10mm, the base values of 20%, 50%, 70% and 90% are respectively used for polishing. The grading polishing sequence is as follows: the first time sanding was done at 2mm or 20% of the maximum allowable pit depth. Then carrying out magnetic powder detection and rechecking, if the defects are not polished, polishing according to the maximum allowable pit depth of 5mm, 7mm, 9mm or 50%, 70% and 90% in sequence according to the previous method, and if the defects are not polished yet when polishing according to the maximum allowable pit depth of 90%, welding and repairing are carried out by manually constructing a scaffold;
The pit polishing head (40) is an arc bottom, the width is more than three times of the arc depth h, for example, cmax is more than or equal to 10mm, and pit shapes and sizes formed by classifying polishing of the pit polishing head (40) are respectively as follows:
if Cmax is smaller than 10mm, pit polishing heads (40) polish in grades to form pit shapes with the following sizes:
C 1 :20％C max mm
B 1 :mm
A 1 :mm
C 1 :50％C max mm
B 1 :mm
A 1 :mm
C 1 :70％C max mm
B 1 :mm
A 1 :mm
C 1 :90％C max mm
B 1 :mm
A 1 :mm
the grinding of the grinding head (19) is judged as follows:
the descending distance of the grinding and leveling grinding head (19) is mainly controlled, and if sparks are observed at the corners of the grinding and leveling grinding head (19), the fact that the welding line is ground can be judged;
the pit polishing grinding head (40) is used for judging that the pit is polished in place:
the actual descending distance of the pit polishing head (40) can be known and fed back to the position adjusting module by mainly controlling the descending distance of the pit polishing head (40) and monitoring the pit depth in real time through the laser automatic navigator (19).
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117464266A (en) * | 2023-12-27 | 2024-01-30 | 中铁四局集团有限公司 | Welding equipment and welding method for arc-shaped steel box girder plate unit |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117464266A (en) * | 2023-12-27 | 2024-01-30 | 中铁四局集团有限公司 | Welding equipment and welding method for arc-shaped steel box girder plate unit |
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