CN117680796A - Intelligent submerged arc welding method and system for stainless steel composite plate - Google Patents
Intelligent submerged arc welding method and system for stainless steel composite plate Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 383
- 238000000034 method Methods 0.000 title claims abstract description 79
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- 239000002184 metal Substances 0.000 claims description 16
- 230000007547 defect Effects 0.000 claims description 14
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 12
- 238000005253 cladding Methods 0.000 claims description 11
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- 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
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
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- 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
- B23K9/00—Arc welding or cutting
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Abstract
The invention discloses an intelligent submerged arc welding method and system for a stainless steel composite plate, which relate to the technical field of welding, and the method comprises the following steps: machining a groove at a welding position of a stainless steel composite plate to be welded, and setting two datum points at the tail end position of the groove; groove detection is carried out by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, and the length and the linear speed of an electric arc are adjusted in real time in the welding process; performing interpolation calculation on the welding seam temperature data obtained by the infrared detector, generating a welding seam temperature distribution cloud picture, and marking the position with larger temperature deviation; carrying out automatic welding material replacement and distribution operation by utilizing a pre-designed welding wire replacement and distribution device; and (3) finishing welding the front base layer part between the two stainless steel composite plates. The invention improves the welding accuracy by adjusting the length and the linear speed of the electric arc in real time, provides welding guidance by marking the position with larger temperature deviation, and has more flexible and efficient whole welding process.
Description
Technical Field
The invention relates to the technical field of welding, in particular to an intelligent submerged arc welding method and system for a stainless steel composite plate.
Background
A stainless steel composite plate is a metal material composed of two or more materials and having stainless steel characteristics. For example, the base layer material is carbon steel or low alloy steel, the cladding layer material is stainless steel, and the base layer and the cladding layer are combined together through specific processing technology such as explosion, rolling or explosion rolling to form a novel metal material. The stainless steel composite board has good tolerance to corrosive media such as acid, alkali, salt and the like, and the price of the stainless steel composite board is relatively low. The stainless steel composite board is widely applied to the fields of petroleum, chemical industry, salt industry, food processing, medicine, environmental protection and the like.
In the field of welding technology, the welding method and the choice of welding material are critical for the quality and efficiency of the weld. Different materials and processes have various welding methods, wherein submerged arc welding is a widely applied welding technology, and welding is performed by covering flux around an electric arc and utilizing a high-temperature melting welding wire of the electric arc and a base metal, so that the submerged arc welding method has the advantages of high efficiency, low cost and the like. However, the stainless steel composite plate is composed of two or more materials, and there is a large difference in physical and chemical properties, so that various problems easily occur during welding. For example, thermal stresses tend to occur during the welding process due to the different coefficients of thermal expansion of the base and the multiple layers, resulting in cracking or deformation of the weld. In addition, due to the chemical composition difference of the base layer and the composite layer, defects such as unfused slag inclusion and the like are easy to occur in the welding process.
The existing welding method of the stainless steel composite plate generally comprises the steps of submerged-arc welding the base layer and then repair welding the multiple layers. While the impact of thermal stress and chemical composition differences on weld quality can be reduced, this approach still has some problems. For example, due to the difference in melting points of the base layer and the multiple layers, a fusion failure or an unfused phenomenon is liable to occur. Meanwhile, the method requires a great deal of time and labor to carry out welding operation, and the welding quality is unstable. Because of the influence of human factors and machining precision, the sizes of different positions of the grooves are different, so that the arc lengths of the different groove positions in the welding process are different, and the welding quality is different. Due to the complex groove shape and welding line process parameters, accurate control of the welding process cannot be realized, and the welding efficiency and quality are seriously affected.
Therefore, a new intelligent submerged arc welding method for the stainless steel composite plate is needed to improve welding quality and efficiency.
Disclosure of Invention
In view of the foregoing, the present invention has been developed to provide an intelligent submerged arc welding method and system for stainless steel composite panels that overcome all or at least some of the above-discussed problems.
According to one aspect of the invention, there is provided an intelligent submerged arc welding method for a stainless steel composite plate, comprising:
step 1, processing a groove at a welding position of a stainless steel composite plate to be welded, and setting two datum points at the tail end position of the groove, wherein the width of the groove is set according to the diameter of an electrode, penetration, the density of molten metal and welding energy;
step 2, groove detection is carried out by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, the length and the linear speed of an electric arc are adjusted in real time in the welding process, and defects and fluctuation in the welding process are reduced, wherein the length of the electric arc is adjusted according to the electric arc voltage, the electric arc current and welding wire parameters;
step 3, carrying out interpolation calculation on the welding seam temperature data obtained by the infrared detector, generating a welding seam temperature distribution cloud picture, and identifying the position with larger temperature deviation;
step 4, automatically replacing and distributing welding materials by utilizing a pre-designed welding wire replacing and distributing device;
and 5, firstly welding a base layer welding seam of a bevel on one side of the composite layer, then shoveling a root from the back surface, filling the bevel on the back surface, and finally welding a transition layer and the composite layer welding seam until the welding of the front surface base layer part between two stainless steel composite plates is completed.
Further, in step 1, the set expression of the width of the groove is:
wherein W is groove width, d is electrode diameter, H is penetration, ρ is density of molten metal, g is gravitational acceleration, P is welding energy, and α is empirical coefficient.
Further, in step 2, the adjustment expression of the length of the arc length is:
wherein L is the length of an arc, U is the arc voltage, I is the arc current, pi is the circumference ratio, D is the diameter of a welding wire, and R is the resistivity of the welding wire;
the expression of the linear velocity is:
wherein V is the linear speed, beta is the empirical coefficient, D is the diameter of the welding wire, pi is the circumference ratio, n is the wire feeding speed, and r is the radius of rotation.
Further, in step 3, the expression of the temperature distribution cloud chart is:
wherein T is temperature, E is object emissivity, T is response time of the thermal imager, A is mirror surface area of the thermal imager, and I is radiation source emissivity.
In step 3, the formula for performing interpolation calculation on the weld temperature data obtained by the infrared detector is as follows:
T interp ＝Interpolation(T ori ,ΔT,α,T amb ,T base ,R update ,autoWeight)
wherein T is interp For Interpolation of the obtained temperature values, interpolation (I) is an Interpolation function, T ori For the original temperature data, deltaT is the temperature difference, alpha is the temperature correction coefficient, T amb Is the ambient temperature value, T base R is the reference temperature value update To dynamically update the neighborhood radius, autoWeight is an adaptive weight.
In step 5, the welding the base layer weld of the bevel on one side of the clad layer, then shoveling the root from the back, filling the bevel on the back, and finally welding the transition layer and the clad layer weld further comprises:
and filling the back groove by using a filling material of titanium alloy or nickel base alloy, and spraying an anti-corrosion coating around the welding line of the transition layer for reinforcement treatment after the welding of the front base layer is completed.
Further, automatically detecting the distance from the end of the welding wire to the root of the groove by a laser radar device, and taking the distance as the initial arc length;
performing self-adaptive analysis according to the initial arc length and preset welding control parameters to generate a welding gun height adjustment strategy;
and sending a command to a welding gun movement mechanism according to the welding gun height adjustment strategy, and adaptively adjusting the height of the welding gun to ensure that the arc length between the welding wire and the workpiece in the welding process is always kept within a preset range.
Further, the welding gun height adjustment strategy specifically comprises the following steps:
wherein D is the arc length monitored in real time, D preset For the preset arc length, the tolerance is the acceptable range of the arc length, and is used for judging whether the arc length is in the ideal range, when the real-time monitored arc length D is larger than the preset arc length D preset When the height of the welding gun is equal to the sum of the tolerance, the height of the welding gun needs to be reduced; when the arc length is greater than or equal to the preset arc length D preset Difference from the tolerance and equal to or less than a predetermined arc length D preset When the height of the welding gun is equal to the sum of the tolerance, the height of the welding gun is kept unchanged; when the arc length D is smaller than the preset arc length D preset And when the difference is the tolerance, the height of the welding gun is increased.
Further, according to the three-dimensional coordinates of the groove root and the vertical distance between the bottom of the welding gun and the groove root, the Z-direction coordinates of the bottom of the welding gun at each welding point are calculated, and the Z-direction coordinates of the welding points are as follows:
Zq i ＝Zp i +ΔZ
wherein Zq i Is the Z-direction coordinate, zp, of the bottom of the welding gun at the ith welding point i The Z-direction coordinate of the ith groove root is the fixed vertical distance between the bottom of the welding gun and the groove root;
and drawing a corresponding relation curve between the Z-direction coordinate of the welding point and the corresponding groove root coordinate, and determining the groove position coordinate which needs to be subjected to welding gun position adjustment according to the corresponding relation curve.
According to another aspect of the present invention, there is provided an intelligent submerged arc welding system for a stainless steel composite plate, comprising:
the welding preparation module is used for processing a groove at the welding position of the stainless steel composite plate to be welded, and setting two datum points at the tail end position of the groove, wherein the width of the groove is set according to the diameter of an electrode, the penetration depth, the density of molten metal and the welding energy;
the arc length adjusting module is used for performing groove detection by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, adjusting the length and the linear speed of an arc in real time in the welding process, and reducing defects and fluctuation in the welding process, wherein the length of the arc is adjusted according to the arc voltage, the arc current and welding wire parameters;
the temperature distribution cloud image generation module is used for carrying out interpolation calculation on the welding seam temperature data acquired by the infrared detector, generating a welding seam temperature distribution cloud image and identifying the position with larger temperature deviation;
the welding material processing module is used for automatically replacing and distributing welding materials by utilizing a pre-designed welding wire replacing and distributing device;
and the welding seam filling module is used for firstly welding the basic layer welding seam of the groove on one side of the cladding layer, then filling the groove on the back surface from the back surface shovel root, and finally welding the transition layer and the cladding layer welding seam until the welding of the front surface basic layer part between the two stainless steel composite boards is completed.
According to the scheme provided by the invention, step 1, a groove is processed at a welding position of a stainless steel composite plate to be welded, and two datum points are arranged at the tail end position of the groove, wherein the width of the groove is set according to the diameter of an electrode, the penetration depth, the density of molten metal and the welding energy; step 2, groove detection is carried out by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, the length and the linear speed of an electric arc are adjusted in real time in the welding process, and defects and fluctuation in the welding process are reduced, wherein the length of the electric arc is adjusted according to the electric arc voltage, the electric arc current and welding wire parameters; step 3, carrying out interpolation calculation on the welding seam temperature data obtained by the infrared detector, generating a welding seam temperature distribution cloud picture, and identifying the position with larger temperature deviation; step 4, automatically replacing and distributing welding materials by utilizing a pre-designed welding wire replacing and distributing device; and 5, firstly welding a base layer welding seam of a bevel on one side of the composite layer, then shoveling a root from the back surface, filling the bevel on the back surface, and finally welding a transition layer and the composite layer welding seam until the welding of the front surface base layer part between two stainless steel composite plates is completed. The invention improves the welding accuracy by adjusting the length and the linear speed of the electric arc in real time, provides welding guidance by marking the position with larger temperature deviation, and has more flexible and efficient whole welding process.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to designate like parts throughout the figures. In the drawings:
FIG. 1 shows a schematic flow diagram of an intelligent submerged arc welding method for a stainless steel composite plate according to an embodiment of the invention;
FIG. 2 shows a schematic structural diagram of an intelligent submerged arc welding system for a stainless steel composite plate according to an embodiment of the invention
Detailed Description
Exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
Fig. 1 shows a schematic flow chart of an intelligent submerged arc welding method for a stainless steel composite plate according to an embodiment of the invention. Specifically, the method comprises the following steps:
step S101, machining a groove at a welding position of the stainless steel composite plate to be welded, and setting two datum points at the tail end position of the groove.
In the embodiment, two stainless steel composite plates to be welded are selected, so that the surfaces of the stainless steel composite plates are clean and free of impurities. For example, a groove is machined in a welding position by using a cutting machine or a plasma cutting machine, and the depth and the width of the groove can be adjusted according to actual needs. At the end position of the groove, two datum points are arranged by using a marker pen or a drilling mode, and the datum points are used for determining the position and the angle of a welding gun and ensuring the accuracy and the stability of the welding process. Then, two stainless steel composite plates are assembled according to the requirement, and fixed on a workbench by using a fixture or a bracket and other fixing devices, so that the position and the angle of the composite plates are ensured to be accurate. The welding gun is placed at the position of the tail end of the groove, the wire outlet nozzle of the welding gun is aligned to two datum points, and the angle and the position of the welding gun are adjusted, so that the welding wire can smoothly fill the groove.
The width of the groove is set according to the electrode diameter, penetration, density of molten metal, and welding energy. Wherein, the size of the electrode diameter directly influences the distribution and conduction of welding current, and further influences the penetration and the flow of molten metal. The penetration is the depth of the molten metal diffusing on the base metal in the welding process, and the required penetration can be set by adjusting parameters such as welding current, welding time, electrode pressure and the like. The density of the molten metal can affect its fluidity and filling effect during the welding process. Therefore, the density of the materials used and their variation during welding need to be taken into account when setting the groove width. The welding energy refers to the total energy input to the welding zone during the welding process, and can be determined by calculating arc heat, resistance heat and the like, and the calculation of the welding energy helps to better control the welding process and the weld quality. The width of the groove is set by the diameter of the electrode, the penetration, the density of the molten metal and the welding energy, so that a better welding effect is obtained.
Further, the set expression of the width of the groove is:
wherein W is groove width, d is electrode diameter, H is penetration, ρ is density of molten metal, g is gravitational acceleration, P is welding energy, and α is empirical coefficient.
Excessive groove widths result in increased difficulty of machining and waste of materials, while too small groove widths affect welding quality and reliability. The groove width needs to take into account the interaction between several factors to obtain a better weld result. Substituting the collected or measured electrode diameter, penetration, molten metal density and welding energy into the above formula to calculate to obtain the groove width.
Step S102, groove detection is carried out by using a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, and the length and the linear speed of an electric arc are adjusted in real time in the welding process, so that defects and fluctuation in the welding process are reduced.
Specifically, according to the shape and the size of the groove to be detected, a laser tracker or a three-dimensional scanner is installed at a proper position, so that the equipment can capture the surface of the complete groove and can cover the required measurement range. Setting related parameters of a laser tracker or a three-dimensional scanner according to the material, the size and the precision requirements of the groove. Such as measurement range, resolution, measurement accuracy, etc. Starting a laser tracker or a three-dimensional scanner, scanning and measuring the groove, automatically collecting surface point cloud data of the groove, and generating a three-dimensional model.
According to three-dimensional data or a model of groove detection, initial arc length and linear speed parameters are set, during welding, a sensor or a monitoring system is used for monitoring the length and linear speed of an arc in real time, and when defects or fluctuation is detected, the length and the linear speed of the arc are automatically adjusted so as to reduce the defects and the fluctuation in the welding process and maintain the stability and the consistency of the welding process.
In this embodiment, the length of the arc is adjusted according to the arc voltage, the arc current, and the welding wire parameters. During the welding process, the voltage and the current of the arc are monitored in real time, so that the combustion state and the energy distribution of the arc can be reflected. Parameters such as the diameter and material of the wire also affect the length of the arc. The optimum arc voltage, current and wire parameter combination may be determined through experimentation and verification. By constantly adjusting and optimizing these parameters, the arc length adjustment scheme best suited to the particular materials and process conditions can be found.
Further, the adjustment expression of the length of the arc length is:
wherein L is the length of the arc, U is the arc voltage, I is the arc current, pi is the circumference ratio, D is the wire diameter, and R is the resistivity of the wire. The length L of the arc refers to the distance between the ends of the arc (between the electrode and the welding material) when the arc burns, and is an important factor in the stability of the arc burning and the quality of the weld. The arc voltage U refers to the voltage difference across the arc, and has a certain relationship with the arc length, and generally increases with the increase of the arc length. The arc current I is the value of the current flowing through the arc and its magnitude directly affects the heat input to the weld, thereby affecting weld quality and efficiency. The wire diameter D is the cross-sectional diameter of the wire, the size of which affects the heat input, penetration, weld width, etc. during welding. The resistivity R of the welding wire is used for measuring the conductivity of the welding wire, and is expressed in omega mm 2 And/m, which affects the combustion and thermal efficiency of the arc and thus the welding process and result. The parameters are related to each other, and the welding process and the welding result are influenced together.
The expression of the linear velocity is:
wherein V is the linear speed, beta is the empirical coefficient, D is the diameter of the welding wire, pi is the circumference ratio, n is the wire feeding speed, and r is the radius of rotation. The linear velocity V refers to the velocity at which the wire moves in the welding direction, which determines the welding efficiency, and is an important parameter for controlling the welding quality and efficiency. The empirical coefficient beta is used to adjust and optimize other parameters in the welding process, and is determined according to actual welding experience. Wire diameter D is the cross-sectional diameter of the wire that determines the heat input, penetration, weld width, etc. during welding. Wire feed speed n is the speed at which the wire is fed into the arc, and is related to the wire speed, which can be controlled by adjusting the wire feed speed. The radius of rotation r refers to the distance from the center of the wire to the axis of rotation when rotating or swinging the welding torch, which determines parameters such as penetration and width. Proper line speed can help to keep the welding process stable, reducing the occurrence of defects and problems. By controlling the linear speed, the length and the shape of the welding seam can be accurately controlled, so that the use and waste of materials are reduced, and the production cost is reduced.
And step S103, carrying out interpolation calculation on the welding seam temperature data obtained by the infrared detector, generating a welding seam temperature distribution cloud picture, and identifying the position with larger temperature deviation.
Specifically, an infrared detector is used for scanning around the welding seam to obtain temperature data of each position of the welding seam. The infrared detector generates a two-dimensional array containing temperature data, where each element represents a pixel temperature value. And preprocessing the acquired temperature data, including outlier removal, smoothing and the like, so as to improve the accuracy of subsequent interpolation calculation. And adopting proper interpolation algorithm (such as linear interpolation, polynomial interpolation, spline interpolation and the like) to perform interpolation calculation on the preprocessed temperature data so as to generate a more accurate temperature distribution cloud chart. The goal of the interpolation is to estimate the temperature distribution across the weld area based on known temperature data points. And visualizing the temperature data obtained by interpolation calculation to generate a weld temperature distribution cloud picture. The temperature distribution cloud graph can be displayed in a two-dimensional or three-dimensional form, wherein colors or gray scales represent the temperature, and different colors or gray scales correspond to different temperature ranges. In the temperature distribution cloud chart, positions with larger temperature deviation are identified through differences of colors or gray levels. And according to the identified position with larger temperature deviation, analyzing the temperature distribution condition of the welding line by combining the temperature distribution cloud picture. And aiming at the region with larger temperature deviation, welding process parameters (such as current, voltage, welding speed and the like) are adjusted to optimize the welding process and improve the welding quality.
Further, the expression of the temperature distribution cloud chart is:
wherein T is temperature, E is object emissivity, T is response time of the thermal imager, A is mirror surface area of the thermal imager, and I is radiation source emissivity.
In this embodiment, the temperature T represents a physical quantity of the thermal state or heat of the object, reflecting the heat distribution of the weld bead and its surrounding area. The emissivity E of an object represents the ability of the surface of the object to radiate energy, and the emissivity of different materials may vary, as may the emissivity of the same material at different temperatures and surface conditions. The response time t of the thermal imager is the time interval from the reception of radiation to the output of the measurement by the thermal imager, and affects the capture capacity of the thermal imager for rapid temperature changes. The thermal imager mirror surface area a is the area of the thermal imager that receives radiation, which affects the total amount of radiation received, and thus the measured temperature value. The radiation source emissivity I represents the intensity of energy radiated outward by the radiation source, and is related to temperature and emissivity.
Furthermore, the formula for performing interpolation calculation on the weld temperature data acquired by the infrared detector is as follows:
T interp ＝Interpolation(T ori ,ΔT,α,T amb ,T base ,R update ,autoWeight)
wherein T is interp For Interpolation of the obtained temperature values, interpolation (I) is an Interpolation function, T ori Is as the originInitial temperature data, delta T is temperature difference, alpha is temperature correction coefficient, T amb Is the ambient temperature value, T base R is the reference temperature value update To dynamically update the neighborhood radius, autoWeight is an adaptive weight. T (T) interp And the result obtained after the processing of the welding seam temperature data by the interpolation algorithm is used for estimating the temperature distribution in the welding seam area. Interpolation (level) is used to interpolate temperature data to generate a more accurate cloud image of the temperature distribution, and common Interpolation algorithms include linear Interpolation, polynomial Interpolation, spline Interpolation, and the like. T (T) ori For the raw temperature data acquired by the infrared detector, the raw temperature data can be represented in the form of a two-dimensional array, wherein each element represents the temperature value of one pixel point. The temperature difference Δt represents the difference between temperatures at two different times or different locations for evaluating temperature variation or analyzing non-uniformity of temperature distribution. A temperature correction coefficient alpha. And correcting the original temperature data to eliminate the influence of environmental factors, instrument errors and the like on the measurement result, and improve the accuracy and reliability of the temperature data. Ambient temperature value T amb The temperature of the surrounding environment during measurement, which affects the measurement result of the infrared detector, can be corrected by taking the ambient temperature as a reference value. Reference temperature value T base The temperature of a certain fixed reference point is represented, and in the weld temperature analysis, the reference temperature value is used for evaluating whether the temperature distribution of the weld meets the process requirements. Dynamically updating neighborhood radius R update The temperature analysis method can dynamically adjust according to actual needs and algorithm logic so as to realize more accurate temperature analysis. The adaptive weighting autoweight is used for more accurately estimating the temperature distribution of the welding line so as to process temperature data of different positions.
Step S104, the welding material is automatically replaced and distributed by using a pre-designed welding wire replacing and distributing device.
In particular, first, means are devised for automatically changing and dispensing welding wire, such as a container comprising a stored welding wire, a take-out device for taking the welding wire from the container, and a dispensing device for dispensing the welding wire to a welding apparatus, which means can be implemented by controlling the automatic operation of the system control device, without limitation. For example, the welding wire is placed into a reservoir so that the welding wire can be continuously supplied during a continuous welding process. When the welding wire needs to be replaced, the material taking device automatically takes out new welding wire from the storage. The reclaimer should ensure a continuous and stable supply of welding wire. The dispensing device automatically dispenses the removed welding wire to the welding equipment. The dispensing device ensures that the welding wire is accurately delivered to the welding location. The control system ensures continuity and stability of the welding process by setting the time intervals and the number of automatic replacement and dispensing of welding wire. By the aid of the device, welding efficiency can be improved, manual intervention is reduced, and stability of welding quality is ensured.
Step S105, firstly welding a base layer welding seam of a bevel on one side of the cladding, then shoveling a root from the back surface, filling the bevel on the back surface, and finally welding a transition layer and the cladding welding seam until the welding of the front surface base layer part between two stainless steel composite boards is completed.
Specifically, the butt joint of two stainless steel composite plates is smooth and seamless. If there is a gap, filling or adjustment is required to ensure weld quality. The base layer portion may be welded using a base layer weld welding process (e.g., submerged arc welding, gas shielded welding, etc.) from the side of the cladding. And (3) carrying out root shoveling treatment from the back surface after the welding of the base layer weld joint is finished, wherein the root shoveling purpose is to remove the root of the base layer weld joint, so that the base layer and the multiple layers can be combined better. After the root is finished, the back groove is filled with a suitable filler material (e.g., wire, rod, etc.). In the filling process, good fusion of the filling material with the base layer and the multi-layer material is ensured, and the defects of air holes, slag inclusion and the like are avoided. And after the back groove is filled, starting to weld the transition layer and the multi-layer weld joint. The transition layer aims to smoothly transition between the base layer and the composite layer and reduce stress concentration. And after the welding of the transition layer and the multi-layer weld joint is finished, the welding of the front base layer part is finished. Through the steps, the welding quality of the stainless steel composite board can be ensured, and the overall performance and the service life of the stainless steel composite board are improved.
Furthermore, the welding of the base layer weld joint of the bevel on one side of the cladding layer firstly, then filling the bevel on the back from the back shovel root, and finally welding the transition layer and the cladding layer weld joint further comprises:
and filling the back groove by using a filling material of titanium alloy or nickel base alloy, and spraying an anti-corrosion coating around the welding line of the transition layer for reinforcement treatment after the welding of the front base layer is completed.
In the embodiment, the titanium alloy and the nickel-based alloy have excellent welding performance and corrosion resistance, and are used as filling materials, and the proper titanium alloy or nickel-based alloy filling materials are selected according to the material and welding requirements of the stainless steel composite plate. In the process of filling the back groove, a titanium alloy or nickel-based alloy filling material can be melted into the back groove by adopting a proper welding process (such as argon tungsten-arc welding, gas metal arc welding and the like). Ensures that the filling material is well fused with the base layer and the multi-layer material, and has no defects of air holes, slag inclusion and the like. And (3) welding the front base layer part according to the sequence of welding the base layer welding seam, shoveling the root, filling the back groove, welding the transition layer and the multi-layer welding seam, so as to ensure that the whole welding area is free from defects and leakage. And after the front base layer part is welded, spraying an anti-corrosion coating around the welding seam of the transition layer. Proper anti-corrosion coating materials such as anti-rust paint, galvanization and the like are selected, so that the coating is ensured to be uniform and continuous, and the base layer and the multi-layer materials can be effectively isolated to prevent corrosive medium from invading. After the anti-corrosion coating is sprayed, strengthening treatment is carried out on the periphery of the welding line of the transition layer, such as local heat treatment, machining or reinforcing ribs addition, etc., so as to improve the fatigue resistance and structural stability of the welding line.
Further, automatically detecting the distance from the end of the welding wire to the root of the groove by a laser radar device, and taking the distance as the initial arc length;
performing self-adaptive analysis according to the initial arc length and preset welding control parameters to generate a welding gun height adjustment strategy;
and sending a command to a welding gun movement mechanism according to the welding gun height adjustment strategy, and adaptively adjusting the height of the welding gun to ensure that the arc length between the welding wire and the workpiece in the welding process is always kept within a preset range.
Specifically, adaptive analysis is performed according to the initial arc length and preset welding control parameters, the adaptive analysis comprises arc stability assessment, analysis of the relation between wire feeding speed and current and voltage and the like, and a welding gun height adjustment strategy is generated according to the result of the adaptive analysis. For example, if the arc length becomes shorter, the torch height needs to be increased, whereas the torch height needs to be decreased. The generated welding gun height adjustment strategy is converted into a specific instruction and sent to a welding gun movement mechanism through a control system, wherein the welding gun movement mechanism can be a mechanical arm, an electric sliding table or other movement devices.
Further, the welding gun height adjustment strategy specifically comprises the following steps:
wherein D is the arc length monitored in real time, D preset The tolerance is an acceptable range of the arc length for judging whether the arc length is in an ideal range. When the real-time monitored arc length D is greater than the preset arc length D preset When summed with the tolerances, it is desirable to reduce the height of the torch to shorten the arc length. When the arc length is greater than or equal to the preset arc length D preset Difference from the tolerance and equal to or less than a predetermined arc length D preset And when the sum of the tolerance is reached, the height of the welding gun is kept unchanged. When the arc length D is smaller than the preset arc length D preset And the difference between the tolerance and the height of the welding gun is increased to increase the arc length. In the whole welding process, the height of the welding gun can be adjusted in real time according to an adjusting strategy by monitoring the change of the arc length.
Further, according to the three-dimensional coordinates of the groove root and the vertical distance between the bottom of the welding gun and the groove root, the Z-direction coordinates of the bottom of the welding gun at each welding point are calculated, and the Z-direction coordinates of the welding points are as follows:
Zq i ＝Zp i +ΔZ
wherein Zq i Is the Z-direction coordinate, zp, of the bottom of the welding gun at the ith welding point i Is the Z-direction coordinate of the root of the ith groove, and delta Z is the bottom and the bottom of the welding gunA fixed vertical distance of the groove root;
and drawing a corresponding relation curve between the Z-direction coordinate of the welding point and the corresponding groove root coordinate, and determining the groove position coordinate which needs to be subjected to welding gun position adjustment according to the corresponding relation curve.
Specifically, using a measuring tool or a sensor, a X, Y, Z coordinate value of the groove root at the i-th welding point, which is the position of the groove on the workpiece, is obtained. And determining a fixed vertical distance between the bottom of the welding gun and the root of the groove according to preset or known parameters so as to ensure that the relative positions of the welding gun and the workpiece are stable in the welding process. And adjusting the height of the welding gun according to the calculated Z-direction coordinate of the bottom of the welding gun, and ensuring that the arc length is within a preset range, thereby improving the welding quality. And collecting the Z-direction coordinates of the bottom of the welding gun at each welding point and the Z-direction coordinates of the corresponding groove root. The collected data is plotted using a plotting tool or software into a scatter plot or graph. And selecting a proper curve function (such as a linear equation, a quadratic equation and the like) for fitting according to the distribution condition of the data points so as to describe the corresponding relation between the bottom of the welding gun and the Z-direction coordinates of the root of the groove. And judging whether each welding point deviates from the expected corresponding relation according to the standard or the preset threshold value of the fitting curve. For example, if the actual gun bottom Z coordinate differs significantly from the coordinate values predicted from the fitted curve, the point is considered to deviate from the expected position. And determining groove position coordinates for welding gun position adjustment according to the deviation condition, wherein the coordinate points can be positions with large difference between the Z-direction coordinates of the bottom of the actual welding gun and the expected values. And adjusting the height of the welding gun or other relevant parameters according to the determined groove position coordinates so as to correct the deviation condition. For example, the Z-coordinate of the bottom of the gun is recalculated and the gun position is adjusted accordingly. Wherein Zq i For the Z-direction coordinate of the bottom of the welding gun at the ith welding point, the vertical position of the bottom of the welding gun at the ith welding point is expressed, and the position of the welding gun in the vertical direction is determined by adjusting Zq i The length of the arc can be precisely controlled. Zp i The Z-axis coordinate value of the i-th groove root, which represents the Z-axis coordinate value of the position on the i-th welding point at which the welding is to be started, i.e., the position on the workpiece,the root of the groove is the place where welding starts, so the Z-direction coordinate of the groove determines the relative position of the arc and the workpiece, and the welding quality is further affected. By adjusting Zp i The arc can be ensured to be correctly aligned with the groove, and the reliability and strength of the welding joint are improved. Δz is the fixed vertical distance of welder bottom and groove root, represents the fixed vertical distance between welder bottom and the groove root for ensure that the relative position between welder and the work piece remains unchanged in the welding process, provide stable welding condition, through keeping fixed vertical distance, can ensure that the electric arc length in the welding process is unanimous, improve welding quality and efficiency.
According to the scheme provided by the invention, step 1, a groove is processed at a welding position of a stainless steel composite plate to be welded, and two datum points are arranged at the tail end position of the groove, wherein the width of the groove is set according to the diameter of an electrode, the penetration depth, the density of molten metal and the welding energy; step 2, groove detection is carried out by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, the length and the linear speed of an electric arc are adjusted in real time in the welding process, and defects and fluctuation in the welding process are reduced, wherein the length of the electric arc is adjusted according to the electric arc voltage, the electric arc current and welding wire parameters; step 3, carrying out interpolation calculation on the welding seam temperature data obtained by the infrared detector, generating a welding seam temperature distribution cloud picture, and identifying the position with larger temperature deviation; step 4, automatically replacing and distributing welding materials by utilizing a pre-designed welding wire replacing and distributing device; and 5, firstly welding a base layer welding seam of a bevel on one side of the composite layer, then shoveling a root from the back surface, filling the bevel on the back surface, and finally welding a transition layer and the composite layer welding seam until the welding of the front surface base layer part between two stainless steel composite plates is completed. The invention improves the welding accuracy by adjusting the length and the linear speed of the electric arc in real time, provides welding guidance by marking the position with larger temperature deviation, and has more flexible and efficient whole welding process.
Claims (10)
1. The intelligent submerged arc welding method for the stainless steel composite plate is characterized by comprising the following steps of:
step 1, processing a groove at a welding position of a stainless steel composite plate to be welded, and setting two datum points at the tail end position of the groove, wherein the width of the groove is set according to the diameter of an electrode, penetration, the density of molten metal and welding energy;
step 2, groove detection is carried out by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, the length and the linear speed of an electric arc are adjusted in real time in the welding process, and defects and fluctuation in the welding process are reduced, wherein the length of the electric arc is adjusted according to the electric arc voltage, the electric arc current and welding wire parameters;
step 3, carrying out interpolation calculation on the welding seam temperature data obtained by the infrared detector, generating a welding seam temperature distribution cloud picture, and identifying the position with larger temperature deviation;
step 4, automatically replacing and distributing welding materials by utilizing a pre-designed welding wire replacing and distributing device;
and 5, firstly welding a base layer welding seam of a bevel on one side of the composite layer, then shoveling a root from the back surface, filling the bevel on the back surface, and finally welding a transition layer and the composite layer welding seam until the welding of the front surface base layer part between two stainless steel composite plates is completed.
2. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 1, the set expression of the width of the groove is:
wherein W is groove width, d is electrode diameter, H is penetration, ρ is density of molten metal, g is gravitational acceleration, P is welding energy, and α is empirical coefficient.
3. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1 or 2, wherein in the step 2, the adjustment expression of the length of the arc length is:
wherein L is the length of an arc, U is the arc voltage, I is the arc current, pi is the circumference ratio, D is the diameter of a welding wire, and R is the resistivity of the welding wire;
the expression of the linear velocity is:
wherein V is the linear speed, beta is the empirical coefficient, D is the diameter of the welding wire, pi is the circumference ratio, n is the wire feeding speed, and r is the radius of rotation.
4. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 3, the expression of the temperature distribution cloud chart is as follows:
wherein T is temperature, E is object emissivity, T is response time of the thermal imager, A is mirror surface area of the thermal imager, and I is radiation source emissivity.
5. The intelligent submerged-arc welding method of the stainless steel composite plate according to claim 3, wherein in the step 3, the formula for interpolating the welding seam temperature data obtained by the infrared detector is as follows:
T interp ＝Interpolation(T ori ，ΔT，α，T amb ，T base ，R update ，autoWeigh t)
wherein T is interp For Interpolation of the obtained temperature values, interpolation (I) is an Interpolation function, T ori For the original temperature data, deltaT is the temperature difference, alpha is the temperature correction coefficient, T amb Is the ambient temperature value, T base Is the reference temperatureDegree value, R update To dynamically update the neighborhood radius, autoweight is an adaptive weight.
6. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, wherein in the step 5, the welding of the base layer weld of the bevel on one side of the clad layer firstly, then filling the bevel on the back from the back shovel root, and finally welding the transition layer and the clad layer weld further comprises:
and filling the back groove by using a filling material of titanium alloy or nickel base alloy, and spraying an anti-corrosion coating around the welding line of the transition layer for reinforcement treatment after the welding of the front base layer is completed.
7. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 1, further comprising:
automatically detecting the distance from the end of the welding wire to the root of the groove by a laser radar device, and taking the distance as the initial arc length;
performing self-adaptive analysis according to the initial arc length and preset welding control parameters to generate a welding gun height adjustment strategy;
and sending a command to a welding gun movement mechanism according to the welding gun height adjustment strategy, and adaptively adjusting the height of the welding gun to ensure that the arc length between the welding wire and the workpiece in the welding process is always kept within a preset range.
8. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 7, wherein the welding gun height adjustment strategy is specifically as follows:
wherein D is the arc length monitored in real time, D preset The tolerance is an acceptable range of the arc length, and is used for judging whether the arc length is in an ideal range or not when the arc length is monitored in real timeThe degree D is greater than the preset arc length D preset When the height of the welding gun is equal to the sum of the tolerance, the height of the welding gun needs to be reduced; when the arc length is greater than or equal to the preset arc length D preset Difference from the tolerance and equal to or less than a predetermined arc length D preset When the height of the welding gun is equal to the sum of the tolerance, the height of the welding gun is kept unchanged; when the arc length D is smaller than the preset arc length D preset And when the difference is the tolerance, the height of the welding gun is increased.
9. The intelligent submerged arc welding method of the stainless steel composite plate according to claim 8, further comprising:
according to the three-dimensional coordinates of the groove root and the vertical distance between the bottom of the welding gun and the groove root, the Z-direction coordinates of the bottom of the welding gun at each welding point are calculated, and the Z-direction coordinates of the welding points are as follows:
Zq i ＝Zp i +ΔZ
wherein Zq i Is the Z-direction coordinate, zp, of the bottom of the welding gun at the ith welding point i The Z-direction coordinate of the ith groove root is the fixed vertical distance between the bottom of the welding gun and the groove root;
and drawing a corresponding relation curve between the Z-direction coordinate of the welding point and the corresponding groove root coordinate, and determining the groove position coordinate which needs to be subjected to welding gun position adjustment according to the corresponding relation curve.
10. An intelligent submerged arc welding system for stainless steel composite plates, which is based on the intelligent submerged arc welding method for stainless steel composite plates according to any one of claims 1 to 9, and is characterized by comprising:
the welding preparation module is used for processing a groove at the welding position of the stainless steel composite plate to be welded, and setting two datum points at the tail end position of the groove, wherein the width of the groove is set according to the diameter of an electrode, the penetration depth, the density of molten metal and the welding energy;
the arc length adjusting module is used for performing groove detection by adopting a laser tracker or a high-precision three-dimensional scanner to obtain three-dimensional data, adjusting the length and the linear speed of an arc in real time in the welding process, and reducing defects and fluctuation in the welding process, wherein the length of the arc is adjusted according to the arc voltage, the arc current and welding wire parameters;
the temperature distribution cloud image generation module is used for carrying out interpolation calculation on the welding seam temperature data acquired by the infrared detector, generating a welding seam temperature distribution cloud image and identifying the position with larger temperature deviation;
the welding material processing module is used for automatically replacing and distributing welding materials by utilizing a pre-designed welding wire replacing and distributing device;
and the welding seam filling module is used for firstly welding the basic layer welding seam of the groove on one side of the cladding layer, then filling the groove on the back surface from the back surface shovel root, and finally welding the transition layer and the cladding layer welding seam until the welding of the front surface basic layer part between the two stainless steel composite boards is completed.
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| JP2003181644A (en) * | 2001-12-19 | 2003-07-02 | Hitachi Ltd | Multi-layer pad welding method for x-shaped groove joint |
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