CN117066762A - Full-automatic butt joint detection system for pipe welded junction and working method thereof - Google Patents
Full-automatic butt joint detection system for pipe welded junction and working method thereof Download PDFInfo
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- CN117066762A CN117066762A CN202311263084.3A CN202311263084A CN117066762A CN 117066762 A CN117066762 A CN 117066762A CN 202311263084 A CN202311263084 A CN 202311263084A CN 117066762 A CN117066762 A CN 117066762A
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- 238000001514 detection method Methods 0.000 title claims abstract description 132
- 210000001503 joint Anatomy 0.000 title claims abstract description 28
- 238000000034 method Methods 0.000 title claims abstract description 15
- 238000003466 welding Methods 0.000 claims abstract description 95
- 238000001228 spectrum Methods 0.000 claims abstract description 45
- 238000007689 inspection Methods 0.000 claims abstract description 22
- 239000002184 metal Substances 0.000 claims abstract description 20
- 238000007726 management method Methods 0.000 claims description 32
- 239000000463 material Substances 0.000 claims description 10
- 230000005855 radiation Effects 0.000 claims description 8
- 238000013500 data storage Methods 0.000 claims description 6
- 230000008569 process Effects 0.000 claims description 5
- 238000013441 quality evaluation Methods 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 10
- 229910000831 Steel Inorganic materials 0.000 abstract description 3
- 239000010959 steel Substances 0.000 abstract description 3
- 239000010953 base metal Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000003384 imaging method Methods 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 1
- 208000003464 asthenopia Diseases 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
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- 230000003203 everyday effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000010183 spectrum analysis Methods 0.000 description 1
- 238000007619 statistical method Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
- B23K31/027—Making tubes with soldering or welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Investigating And Analyzing Materials By Characteristic Methods (AREA)
Abstract
The invention discloses a full-automatic butt joint detection system for a pipe welded junction and a working method thereof, belonging to the technical field of metal equipment production. The welding device comprises a database server, a welding unit, a welding seam AI identification unit, a ray detection unit, a spectrum detection unit, a three-dimensional scanning unit, a coding unit, a metal coding machine, a network terminal, a management terminal and a sorting unit; the weld joint AI identification unit is respectively connected with the ray detection unit, the spectrum detection unit and the three-dimensional scanning unit; the management terminal is respectively connected with the database server, the welding unit, the ray detection unit, the spectrum detection unit, the three-dimensional scanning unit, the coding unit and the network terminal; the network terminal is communicated with the database server; the metal coding machine is respectively connected with the coding unit and the sorting unit. The invention can realize automatic, efficient and accurate quality inspection of the welded junction of the steel pipe, can trace the quality, improves the production efficiency, reduces the error rate and has higher practical value.
Description
Technical Field
The invention belongs to the technical field of metal equipment production, and particularly relates to a full-automatic butt joint detection system for a pipe welded junction and a working method thereof.
Background
In power station boiler equipment, steel pipe automatic welding butt welding junction is visible everywhere, and the quality of butt welding junction directly influences the safety in utilization of equipment. The welding and inspection of the welded junction of the traditional pipe are manual semiautomatic welding, and the weld detection is generally performed manually, so that the following defects exist: 1) The semi-automatic welder cannot record welding current, voltage, welding speed and other parameters, when a welding problem occurs in a welding line, statistical analysis cannot be performed, the welder is further optimized by searching reasons, and the problem that a welder uses large current and large voltage for output cannot be prevented; 2) Conventional tube industry TV ray inspection is typically manually performed for film taking and evaluation, and visual fatigue occurs when thousands of welding ray film inspections are repeated every day, resulting in missing of part of defects, and difficulty in forming a weld interior quality inspection statistical table; 3) The traditional weld spectrum inspection is carried out after equipment production is finished, because the position of a weld is not fixed after the equipment production is finished, the condition that omission is easy to exist in manual searching, in addition, a inspector holds spectrum inspection equipment to find the weld to inspect the weld everywhere, missing of the weld spectrum inspection often occurs, and the inspector deliberately changes full inspection into spot inspection because of the detection quantity, so that the weld spectrum inspection result is inaccurate; 4) For thousands to welding line size and appearance inspection, manual inspection by a manufacturing factory often cannot be performed by 100%, so that partial unqualified welded junctions are left to a construction site, and risk is brought to later operation of equipment; 5) When the welding line is subjected to ray detection, spectrum detection, size and appearance inspection, three working procedures are independent and are respectively detected by different detection personnel, and each time the welding line is required to be found, then the welding line is detected, so that the time is very wasted; 6) When detecting problems or questions exist in detection such as crater ray detection or spectrum detection and the like in the installation site, a manufacturer cannot trace back the ray detection negative film and the spectrum record of the weld joint because each crater is not uniquely identified, and hundreds of thousands of weld joint detection results of one part need to be re-checked, so that the workload is huge.
Disclosure of Invention
In order to solve the existing problems, the invention aims to provide a full-automatic butt joint detection system for a pipe welded junction and a working method thereof, which can realize automatic, efficient and accurate quality inspection of the pipe welded junction, can carry out quality tracing, improve the production efficiency, reduce the error rate and have higher practical value.
The invention is realized by the following technical scheme:
the invention discloses a full-automatic butt joint detection system for a pipe welded junction, which comprises a database server, a welding unit, a weld joint AI identification unit, a ray detection unit, a spectrum detection unit, a three-dimensional scanning unit, a coding unit, a metal coding machine, a network terminal, a management terminal and a sorting unit, wherein the database server is used for storing a plurality of welding information;
the weld joint AI identification unit is respectively connected with the ray detection unit, the spectrum detection unit and the three-dimensional scanning unit; the management terminal is respectively connected with the database server, the welding unit, the ray detection unit, the spectrum detection unit, the three-dimensional scanning unit, the coding unit and the network terminal; the network terminal is communicated with the database server; the metal coding machine is respectively connected with the coding unit and the sorting unit.
Preferably, the weld AI recognition unit is an industrial vision-based inspection robot.
Preferably, the radiation detection unit is an industrial X-ray television detection device.
Preferably, the spectrum detection unit is a full spectrum direct-reading spectrometer.
Preferably, the three-dimensional scanning unit is a three-dimensional laser scanner.
Preferably, the encoding unit encodes the detection results of the radiation detection unit, the spectrum detection unit, and the three-dimensional scanning unit, respectively.
Preferably, the metal coding machine is a pneumatic coding machine or a laser coding machine.
Preferably, the network terminal is a mobile phone, a tablet or a PC terminal.
Preferably, the sorting unit is a fully automated manipulator with a code reader.
The invention discloses a working method of the full-automatic butt joint detection system for the welded junction of the pipe, which comprises the following steps of
The welding unit records key parameters and information of a pipe welding process, transmits data to the management terminal, transfers the butted pipe to the welding seam AI recognition unit, detects the welding seam through the ray detection unit, the spectrum detection unit and the three-dimensional scanning unit respectively after the welding seam AI recognition unit recognizes the accurate position of the welding seam, judges whether the welding seam is qualified or not, transmits the detection data and the detection result to the management terminal, and the encoding unit generates a welding seam unique code according to the detection result and feeds back the welding seam unique code to the management terminal, the coding module and the sorting unit respectively; the management terminal sorts the unique weld codes transmitted by the coding unit and the detection data transmitted by the ray detection unit, the spectrum detection unit and the three-dimensional scanning unit into a weld quality information table, and transmits the weld quality information table to the data server for data storage; the metal coding machine is used for coding the unique weld joint codes transmitted by the coding unit on the base metal of the weld joint edges, and the sorting unit is used for identifying the unique weld joint codes transmitted by the coding unit and sorting out the butt joint pipes with unqualified coded information bits; and the manufacturer and the user call the data in the data server through the network terminal, and perform quality evaluation and traceability on the weld seam.
Compared with the prior art, the invention has the following beneficial technical effects:
the full-automatic butt joint detection system for the pipe welded junctions can count the welding parameters and the like of all the pipe butt joint welded junctions, so that welding equipment is optimized, and welding qualification rate is provided; after the weld joint is searched by the weld joint AI recognition module, the ray detection, the spectrum detection, the size and the appearance inspection work are completed at the same time, so that the workload is greatly reduced, and the detection inaccuracy caused by factors such as artificial fatigue is also reduced; when the welding quality of the welding seam is questionable, the network module flat plate end, the mobile phone end or the PC end can be used for retrieving the welding, ray detection, spectrum detection, size and appearance inspection and other data of the welding seam through the unique welding seam code, and the welding seam quality is traced and analyzed. The invention can realize automatic, efficient and accurate quality inspection of the welded junction of the steel pipe, can trace the quality, improves the production efficiency, reduces the error rate and has higher practical value.
The working method of the full-automatic butt joint detection system for the pipe welded junction disclosed by the invention has the advantages of high automation degree, definite division of each unit, effective improvement of production efficiency, reduction of unqualified product rate and good traceability.
Drawings
FIG. 1 is a schematic diagram of the overall structure of the system of the present invention.
In the figure: the welding line detection system comprises a database server 1, a welding unit 2, a welding line AI recognition unit 3, a ray detection unit 4, a spectrum detection unit 5, a three-dimensional scanning unit 6, a coding unit 7, a metal coding machine 8, a network terminal 9, a management terminal 10 and a sorting unit 11.
Detailed Description
The invention will now be described in further detail with reference to the accompanying drawings and specific examples, which are given by way of illustration of the invention and not by way of limitation:
as shown in fig. 1, the full-automatic butt joint detection system for the pipe welded junction comprises a database server 1, a welding unit 2, a welding line AI identification unit 3, a ray detection unit 4, a spectrum detection unit 5, a three-dimensional scanning unit 6, a coding unit 7, a metal coding machine 8, a network terminal 9, a management terminal 10 and a sorting unit 11;
the weld joint AI recognition unit 3 is respectively connected with the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6; the management terminal 10 is respectively connected with the database server 1, the welding unit 2, the ray detection unit 4, the spectrum detection unit 5, the three-dimensional scanning unit 6, the coding unit 7 and the network terminal 9; the network terminal 9 is in communication interconnection with the database server 1; the metal coding machine 8 is connected to the coding unit 7 and the sorting unit 11, respectively.
The welding unit 2 is mainly used for recording key parameters and information of the welding process, such as welding current, welding time, welding material type, etc., and transmitting data to the management terminal 10, which data can be used for subsequent quality traceability and analysis.
In a preferred embodiment of the invention, the weld AI recognition unit 3 is an industrial vision-based inspection robot. The weld joint AI recognition unit 3 is used for accurately recognizing the weld joint position after the pipe butt joint is completed, so that the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6 can further detect the weld joint position.
In a preferred embodiment of the invention, the radiation detection unit 4 is an industrial X-ray television detection device. After the weld position is identified by the weld AI identification module 3, the radiation detection unit 4 can perform industrial TV radiation detection imaging on the weld according to standard requirements, judge whether the internal quality of the weld is qualified, and transmit the judgment result and imaging information to the management terminal 10.
In a preferred embodiment of the invention, the spectrum sensing unit 5 is a full spectrum direct reading spectrometer. The spectrum detection unit 5 performs spectrum analysis and detection on the weld joint and the base materials on two sides of the weld joint, judges whether the weld joint and the base materials are qualified, and transmits the judging result and spectrum detection data to the management terminal 10.
In a preferred embodiment of the invention, the three-dimensional scanning unit 6 is a three-dimensional laser scanner. The three-dimensional scanning unit 6 can perform three-dimensional scanning on the weld and the weld peripheral base material, judge whether the weld is qualified according to the preset quality standard requirement, and transmit the judging result and the scanning result to the management terminal 10.
In a preferred embodiment of the present invention, the encoding unit 7 encodes the detection results of the radiation detection unit 4, the spectrum detection unit 5, and the three-dimensional scanning unit 6, respectively. The encoding unit 7 accesses the judging results of the welding seam by the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6 from the management terminal 10, and each module detects that the qualified code is T and the unqualified code is F. The encoding unit 7 encodes this weld uniquely and transmits the unique code to the management terminal 10 and the metal encoder 8, respectively.
In a preferred embodiment of the invention, the metal code printer 8 is a pneumatic code printer or a laser code printer. The metal coding machine 8 uniquely codes the weld joint input by the coding unit 7 on the base material of the weld joint edge.
In a preferred embodiment of the present invention, the network terminal 9 is a mobile phone, tablet or PC terminal. The management terminal 10 can be accessed and the parameters of all welding and detecting modules can be changed, and the welding and detecting data of each pipe weld in the database server 1 can be accessed and checked simultaneously.
The management terminal 10 collates the weld unique code transmitted from the coding unit 7 and the detection data transmitted from the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6 into a weld quality information table, and transmits the weld quality information table to the database server 1 for data storage.
In a preferred embodiment of the invention, the sorting unit 11 is a fully automated manipulator with a code reader. The sorting unit 11 identifies the unique weld joint code imported by the coding unit 7, and sorts out the butt joint pipes with F contained in the detection result in the code and completed code printing.
The working method of the full-automatic butt joint detection system for the pipe welded junction comprises the following steps:
the welding unit 2 records key parameters and information of a pipe welding process, transmits data to the management terminal 10, transfers the butted pipe into the welding seam AI recognition unit 3, and after the welding seam AI recognition unit 3 recognizes the accurate position of the welding seam, respectively detects and judges whether the welding seam is qualified through the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6, transmits detection data and detection results to the management terminal 10, and the encoding unit 7 generates a welding seam unique code according to the detection results and respectively feeds back to the management terminal 10, the coding module 8 and the sorting unit 11; the management terminal 10 sorts the unique weld codes transmitted by the coding unit 7 and the detection data transmitted by the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6 into a weld quality information table, and transmits the weld quality information table to the data server 1 for data storage; the metal coding machine 8 uniquely codes the welding seam transmitted by the coding unit 7 on a base material of a welding seam edge, and the sorting unit 11 identifies the unique welding seam code transmitted by the coding unit 7 and sorts out the butt joint pipes with unqualified coded information bits; the manufacturer and the user call the data in the data server 1 through the network terminal 9, and perform quality evaluation and tracing on the weld seam.
The invention is further explained in the following by means of a specific example:
the following is a further explanation of the welding and inspection of the 0001 butt weld for the first tube of the high temperature reheater apparatus for a boiler, production code G15:
when welding seam butt joint is completed on the high-temperature reheater equipment pipes of the thermal power boiler of the power station, the welding unit 2 records all current and voltage data of backing welding, middle welding and cover welding in the pipe welding process and transmits the current and voltage data to the management terminal 10, the pipes subjected to butt joint are transferred to the detection system, after the accurate positions of the welding seams are identified by the welding seam AI identification unit 3, the welding seams are respectively detected to be I-level by rays through the ray detection unit 4, the welding seams are qualified, the base materials on two sides of the welding seams are detected to be SA-213S 30434 materials by the spectrum detection unit 5, the welding materials are THERMANIT and HCu meet the technological requirements, and the detection is qualified; the three-dimensional scanning unit 6 scans the welding seam, the welding height of the welding seam is 4mm, the technological requirement is 0-2mm, the standard requirement is not met, and the welding seam is unqualified. The detection data and the detection result are transmitted into the management terminal 10, the encoding unit 7 generates a weld unique code G15-0001-TTF according to the detection result and feeds back to the management terminal 10, the encoding unit 7 and the sorting unit 11, the management terminal 10 sorts the weld unique code transmitted by the encoding unit 7 and the detection data transmitted by the ray detection unit 4, the spectrum detection unit 5 and the three-dimensional scanning unit 6 into a weld quality information table, the weld quality information table is transmitted into the database server 1 for data storage, the metal coding machine 8 beats the weld unique code G15-0001-TTF transmitted by the encoding unit 7 on a base metal of a weld edge, the sorting unit 11 identifies the weld unique code G15-0001-TTF transmitted by the encoding unit 7, the last letter in the codes is F, the appearance detection of the weld size is disqualified, and the tube is sorted out. The management terminal 10 sorts the welding seam unique code G15-0001-TTF transmitted by the coding unit 7, the ray detection unit 4, the spectrum detection unit 5 and the detection data transmitted by the three-dimensional scanning unit 6 into a welding seam quality information table, and transmits the welding seam quality information table to a data server for data storage, and a manufacturer and a user can search the whole welding and detection data of the G15-0001-TTF through a network terminal flat plate, a mobile phone or a PC end, so that the quality evaluation and the tracing of the welding seam are carried out.
The foregoing is merely illustrative embodiments of the present invention, and the present invention is not limited thereto, and any changes or substitutions easily contemplated by those skilled in the art within the scope of the present invention, or equivalent structures or equivalent flow modifications made by the present invention in the description and the accompanying drawings, or direct or indirect application to other related technical fields should be included in the scope of the present invention.
Claims (10)
1. The full-automatic butt joint detection system for the pipe welded junction is characterized by comprising a database server (1), a welding unit (2), a welding line AI recognition unit (3), a ray detection unit (4), a spectrum detection unit (5), a three-dimensional scanning unit (6), a coding unit (7), a metal coding machine (8), a network terminal (9), a management terminal (10) and a sorting unit (11);
the weld joint AI recognition unit (3) is respectively connected with the ray detection unit (4), the spectrum detection unit (5) and the three-dimensional scanning unit (6); the management terminal (10) is respectively connected with the database server (1), the welding unit (2), the ray detection unit (4), the spectrum detection unit (5), the three-dimensional scanning unit (6), the coding unit (7) and the network terminal (9); the network terminal (9) is in communication interconnection with the database server (1); the metal coding machine (8) is respectively connected with the coding unit (7) and the sorting unit (11).
2. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the weld AI recognition unit (3) is an industrial vision-based detection robot.
3. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the radiation detection unit (4) is an industrial X-ray television detection device.
4. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the spectrum detection unit (5) is a full-spectrum direct-reading spectrometer.
5. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the three-dimensional scanning unit (6) is a three-dimensional laser scanner.
6. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the encoding unit (7) encodes the detection results of the radiation detection unit (4), the spectrum detection unit (5) and the three-dimensional scanning unit (6), respectively.
7. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the metal coding machine (8) is a pneumatic coding machine or a laser coding machine.
8. The full-automatic butt joint detection system for pipe welded junctions according to claim 1, wherein the network terminal (9) is a mobile phone, a tablet or a PC terminal.
9. A full-automatic butt joint detection system for pipe ends according to claim 1, characterized in that the sorting unit (11) is a full-automatic manipulator with a code reader.
10. A method of operating a full-automatic pipe weld joint inspection system according to claims 1-9, comprising:
the welding unit (2) records key parameters and information in a pipe welding process, transmits data to the management terminal (10), transfers the butted pipe into the welding seam AI recognition unit (3), and after the welding seam AI recognition unit (3) recognizes the accurate position of the welding seam, respectively detects and judges whether the welding seam is qualified through the ray detection unit (4), the spectrum detection unit (5) and the three-dimensional scanning unit (6), and transmits detection data and detection results to the management terminal (10), and the coding unit (7) generates a welding seam unique code according to the detection results and respectively feeds back to the management terminal (10), the coding module (8) and the sorting unit (11); the management terminal (10) sorts the weld unique codes transmitted by the coding unit (7) and the detection data transmitted by the ray detection unit (4), the spectrum detection unit (5) and the three-dimensional scanning unit (6) into a weld quality information table, and transmits the weld quality information table to the data server (1) for data storage; the metal coding machine (8) is used for coding the unique weld joint codes transmitted by the coding unit (7) on the base material of the weld joint edges, and the sorting unit (11) is used for identifying the unique weld joint codes transmitted by the coding unit (7) and sorting out butt joint pipes with unqualified coded information bits; the manufacturer and the user retrieve the data in the data server (1) through the network terminal (9) and carry out quality evaluation and traceability on the weld seam.
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CN202311263084.3A CN117066762A (en) | 2023-09-27 | 2023-09-27 | Full-automatic butt joint detection system for pipe welded junction and working method thereof |
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CN202311263084.3A CN117066762A (en) | 2023-09-27 | 2023-09-27 | Full-automatic butt joint detection system for pipe welded junction and working method thereof |
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CN202311263084.3A Pending CN117066762A (en) | 2023-09-27 | 2023-09-27 | Full-automatic butt joint detection system for pipe welded junction and working method thereof |
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