CN117798459B - Spherical pressure storage tank welding method and system - Google Patents
Spherical pressure storage tank welding method and system Download PDFInfo
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Abstract
The invention relates to the technical field of welding, in particular to a method and a system for welding a spherical pressure storage tank, comprising the steps of dividing a shell plate of the spherical tank into different position belts according to splicing positions, wherein the same position belt consists of shell plates which are equally divided and have the same shape, welding seams connected between the shell plates of the same position belt are marked as longitudinal seams, welding seams connected between the shell plates of different position belts are marked as circumferential seams, and the longitudinal seams connected between the shell plates of different position belts are staggered; firstly welding longitudinal seams of the bit belts, and then welding circumferential seams among the bit belts; and when the girth is welded, the welding current is regulated according to the obtained contact gap curve. The invention obtains the contact gap curve by obtaining the effective welding time of the welder for initially welding the symmetrical shell plates, thereby obtaining the current contact gap approximately according to the welding progress, and intelligently adjusting the current so as to synchronize the welding progress of the welder; when the welding progress is kept synchronous, the symmetrical shell plate dismantling and hoisting conditions or the transverse positioning blocks among the shell plates can be synchronously dismantled, and the welding period is saved.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a method and a system for welding a spherical pressure storage tank.
Background
The spherical pressure storage tank (hereinafter referred to as spherical tank) has wide application in the energy and chemical industry, and the shell of the spherical tank is spherical and is uniformly stressed; under the condition of the same wall thickness, the bearing capacity of the spherical tank is higher; under the condition of the same volume, the surface area of the spherical container is minimum, so that the wall thickness and the surface area of the spherical tank are small, and a large amount of steel can be saved compared with other shapes. The spherical tank pressure container mainly stores gas or liquefied gas with higher pressure, and most of the gas or liquefied gas is inflammable and explosive medium, so that the spherical tank is difficult to construct and has high quality requirement. The difficulty in the spherical tank installation and construction process is a welding link, and the welded spherical tank must be capable of bearing extreme pressure and temperature conditions. The curved shell plates of the welded spherical tank are several, the thickness of the shell plates is generally 25-50 mm according to design working pressure parameters, and accessories such as a support column for supporting the spherical tank body and an auxiliary valve are arranged besides the shell plates of the spherical tank body. The split structure forms of the main shell plate can be divided into orange-leaf type, football type and mixed type, wherein the tank body of the mixed type spherical tank is composed of an equatorial belt and a temperate belt which adopt orange-leaf type, and the polar plate adopts football-leaf type structure. Because the structure takes the advantages of orange-leaf type and football-leaf type structures, the material utilization rate is higher, the length of the welding line is shortened, the number of the shell plates is smaller, and the structure is particularly suitable for large-scale spherical tanks. The mixed spherical tank divides the shell plate into an equatorial band, an upper temperature zone, a lower temperature zone, an upper cold zone, a lower cold zone and an upper polar zone according to the region forming the spherical tank, and the shell plates between the equatorial band, the temperature zone, the cold zone and the polar zones are welded and connected, and are fixed by circular seams along the latitude direction and longitudinal seams along the longitude direction. Welding of spherical tanks requires experienced welders to complete, and has the difficulty that the length of the tank weld seam is hundreds of meters, and a large number of welders are required to weld around the spherical tank in a symmetrical manner while simultaneously welding.
Disclosure of Invention
(1) The invention aims to provide a spherical pressure storage tank welding method and a spherical pressure storage tank welding system, which are used for solving the problem of synchronous girth welding progress in the spherical tank welding process.
(2) To achieve the above object, in one aspect, the present invention provides a spherical pressure tank welding method, the method comprising:
dividing the shell plate of the spherical tank into different bit zones according to splicing positions, wherein the bit zones comprise an upper polar zone, an upper cold zone, an upper warm zone, an equatorial zone, a lower warm zone, a lower cold zone and a lower polar zone; the same position belt consists of equally-divided shells with the same shape, the welding seams connected between the shells of the same position belt are marked as longitudinal seams, the welding seams connected between the shells of different position belts are marked as circumferential seams, and the longitudinal seams connected between the shells of different position belts are staggered;
Splicing shells corresponding to the equatorial strips, reserving contact gaps of longitudinal joints between the shells, overlapping longitudinal positioning blocks between the shells, firmly welding the longitudinal positioning blocks by welding and fixing adjacent shells, and finishing the positioning of the shells of the equatorial strips; the method comprises the steps of erecting supporting legs, wherein connecting ribs are fixed between the supporting legs, and a circular plane upper opening formed between the upper ends of the supporting legs is arranged to support the outer side surface of the equator; hoisting the equatorial belt to form an upper opening of a circular plane between the supporting legs, and adjusting the center of the equatorial belt to be placed to coincide with the center of the upper opening of the circular plane; welding longitudinal seams among the shells of the equatorial belt, and firmly welding and fixing the supporting legs and the shells of the equatorial belt;
Splicing the shells corresponding to the upper temperature zone, reserving a contact gap of a longitudinal seam between the shells, overlapping the longitudinal positioning blocks between the shells, firmly welding the longitudinal positioning blocks by welding and fixing the adjacent shells, and completing the positioning of the shells of the upper temperature zone; hoisting the upper temperature belt to the upper part of the equatorial belt for splicing and reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks along the circular seam, and firmly welding and fixing adjacent shell plates between the upper temperature belt and the equatorial belt shell plates through welding spots by overlapping; welding longitudinal seams among the shells of the upper temperature zone, and welding circumferential seams between the shells of the upper temperature zone and the shells of the equatorial zone;
Splicing the shells corresponding to the upper cold zone, reserving a contact gap of a longitudinal seam between the shells, overlapping the longitudinal positioning blocks between the shells, firmly welding the longitudinal positioning blocks by welding and fixing the adjacent shells, and finishing the positioning of the shells of the upper cold zone; hoisting the upper cold zone to the upper temperature zone, splicing and reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks along the circular seam, and firmly welding and fixing adjacent shell plates between the upper cold zone and the upper temperature zone shell plates through welding spots by overlapping; welding longitudinal seams among the shell plates of the upper cold zone, and welding circumferential seams between the upper cold zone and the shell plates of the upper warm zone;
Splicing corresponding shell plates of the upper pole belt, reserving a contact gap of a longitudinal seam between the shell plates, taking a longitudinal positioning block to be overlapped between the shell plates, firmly welding the longitudinal positioning block through welding and fixing the adjacent shell plates, and completing the shell plate positioning of the upper pole belt; hanging the upper polar belt above the upper cold belt for splicing, reserving a contact gap of a circular seam, maintaining a hanging state, uniformly distributing transverse positioning blocks along the circular seam, and firmly welding and fixing adjacent shell plates between the upper polar belt and the upper cold belt shell plates through welding spots by overlapping; welding a longitudinal seam between the shell plates of the upper polar band, and welding a circular seam between the upper polar band and the shell plates of the upper cold band;
The welding method of the upper temperate zone is used for symmetrically completing the welding of the lower temperate zone and the equatorial zone, the welding method of the upper cold zone is used for symmetrically completing the welding of the lower cold zone and the lower temperate zone, and the welding method of the upper polar zone is used for symmetrically completing the welding of the lower polar zone and the lower cold zone; after the welding of the outer slope of the outer side of the spherical tank is finished, the inner side of the spherical tank is back-ground and subjected to nondestructive flaw detection, and then an inner groove of the inner side of the spherical tank is welded;
The girth welding method between the bit bands comprises the following steps: welding construction is carried out by evenly distributing welders around the outer side of the shell plate forming the circular seam, and the initial welding voltage is set And welding initiation current/>All welders arc from the shell plates at symmetrical positions, arc is received when all welders weld to adjacent shell plates and the transverse positioning blocks are required to be removed or the hoisting conditions of the welded shell plates are removed, the consumption amount of welding rods in the welding process of the welders is counted, and effective welding time is obtained according to the consumption amount of the welding rods; according to the effective welding time sequence counted by the welder in sequence, mapping the effective welding time sequence to an average width sequence of the contact gap in the welding process, and fitting according to the width sequence to generate a contact plane where two side bands of the contact gap are positioned; solving a space distance curve between two side bit bands according to the width sequence and the contact plane to obtain a contact gap size curve, and finding a minimum gap value/> on the contact gap size curve; When the current transverse positioning block is dismantled and the next section of contact gap is welded, predicting the current contact gap of a welder according to the contact gap size curve, and according to the current contact gap and the minimum gap value/>Multiple correction welding initiation current/>Obtaining welding correction current/>。
Further, the method for generating the contact plane where the bit bands at two sides of the contact gap are located according to the width sequence fitting comprises the following steps:
Setting a fixed first plane as a contact plane at one side of a contact gap, marking the other contact plane as a second plane, marking the annular projection of the bit zone on the first plane as a first annular, marking the annular projection of the bit zone on the second plane as a second annular, and enabling the first annular and the second annular to be non-parallel and enabling the circle centers of the first annular and the second annular to have no concentric relation; the center of the first ring is taken as the origin of coordinates, and the first ring is arranged at The plane is provided with an included angle vector of the second annular center relative to the first annular center asWherein/>、/>And/>The/>, respectively, of the second ring relative to the first ringAxis,/>Shaft sum/>The Euler angle of the shaft rotation, and the translation vector of the second annular center of a circle relative to the first annular center of a circle is/>; The width sequence formula corresponding to the contact gap is set as:
；
Wherein the method comprises the steps of Is the vector of any point on the second ring,/>Is/>Vectors of perpendicular projection points of the corresponding points on the first ring; the width sequence is the vertical distance from the welding position on the second ring to the first ring, and the error function of the width sequence is set as follows:
；
Wherein the method comprises the steps of Is the/>, in the width sequenceElement,/>Is the number of elements in the width sequence,/>Is the first in the width sequenceA vector corresponding to a point of the element on the first ring; bringing the width sequence into the error function/>And using gradient descent algorithm to fit to obtain included angle vector/>And translation vector/>Thereby obtaining the spatial position of the second ring; the size curve of the contact gap formed between the second circular ring and the first circular ring is obtained through the space position of the second circular ring.
Further, the method further comprises:
When welding correcting current Exceeding a set maximum welding current/>When welding correction current/>Adjusted to the welding maximum current/>Welding initial current/>Adjusted to/>; When welding correction current/>Exceeding a set maximum welding current/>And/>Below a set welding minimum current/>When welding initial current/>Adjusted to welding minimum current/>And welding correction current/>Adjusted to the welding maximum current/>。
Further, the method further comprises:
And after the welding correction current is calculated and validated, counting the number of welding rods consumed by a welder during the next section of shell plate welding to obtain the actual welding time, obtaining a welding line corresponding to the abnormal period of the actual welding time through a Z-score method, and performing nondestructive inspection on the welding line corresponding to the abnormal period of the actual welding time in advance.
Further, the method further comprises:
When welding construction is carried out by welders around the outer sides of the shell plates forming the circular seams in an even distribution mode, the welding seams corresponding to each shell plate are divided into equal-length welding sections, and welding is carried out in a welding direction of the whole shell plates, wherein the welding direction of each welding section is opposite to the welding direction of the whole welding section.
Further, the method further comprises:
before shell plates of the spherical tank are welded, removing dirt on the surface of the spherical shell within the range of at least 15mm on two sides of a welding groove of the shell plates; the shell plate welding groove comprises an outer groove formed on the outer side of the shell plate and an inner groove formed on the inner side of the shell plate, wherein an included angle of the outer groove is 50-60 degrees, an included angle of the inner groove is 55-65 degrees, the depth of the outer groove is 55-65% of the wall thickness, and the depth of the inner groove is 30-45% of the wall thickness.
Further, the method further comprises:
When splicing the shell plates or the bit bands, reserving a contact gap of a welding line to be 2-4 mm; after splicing between the shell plates or the positioning strips is completed, the adjacent shell plates which are not welded and fixed are fixed through welding transverse positioning blocks or longitudinal positioning blocks, and the length of the spot welding seam of the transverse positioning blocks or the longitudinal positioning blocks, which is welded on the shell plates, is at least 10mm.
Further, the method further comprises:
Filling a contact gap between the shell plates or the bit bands through at least two layers of welding layers, wherein each layer of welding layer is 2.5-3.5 mm, and welding heads of each layer are staggered by at least 50mm due to arc starting; and after each layer of welding layer is welded, polishing the uneven welding heads caused by arcing of each layer of welding layer to enable the welding layer to be kept flat.
Further, the method for back chipping and polishing the inner side of the spherical tank comprises the following steps:
Trimming the inner side of the welding seam of the shell plate into a U-shaped gouging groove through a carbon arc gouging machine, wherein the gouging groove depth is kept consistent with the gouging width, the gouging groove depth is 5-6 mm, and the gouging width is 12-16 mm; the gouges are polished to make the surface smooth and carburized free and remove dirt in the gouges.
Based on the same inventive concept, in another aspect, the invention also provides a spherical pressure storage tank welding system, which is applied to the spherical pressure storage tank welding method, and comprises the following steps:
The contact curve estimating module is used for setting a fixed first plane as a contact plane at one side of the contact gap, marking the other contact plane as a second plane, marking the annular projection of the bit zone on the first plane as a first annular, marking the annular projection of the bit zone on the second plane as a second annular, and enabling the first annular and the second annular to be non-parallel and enabling the circle centers of the first annular and the second annular to have no concentric relation; the center of the first ring is taken as the origin of coordinates, and the first ring is arranged at The plane is provided with an included angle vector of the second annular center relative to the first annular center as/>Wherein/>、/>And/>The/>, respectively, of the second ring relative to the first ringAxis,/>Shaft sum/>The Euler angle of the shaft rotation, and the translation vector of the second annular center of a circle relative to the first annular center of a circle is/>; The width sequence formula corresponding to the contact gap is set as:
；
Wherein the method comprises the steps of Is the vector of any point on the second ring,/>Is/>Vectors of perpendicular projection points of the corresponding points on the first ring; the width sequence is the vertical distance from the welding position on the second ring to the first ring, and the error function of the width sequence is set as follows:
；
Wherein the method comprises the steps of Is the/>, in the width sequenceElement,/>Is the number of elements in the width sequence,/>Is the first in the width sequenceA vector corresponding to a point of the element on the first ring; bringing the width sequence into the error function/>And using gradient descent algorithm to fit to obtain included angle vector/>And translation vector/>Thereby obtaining the spatial position of the second ring; obtaining a contact gap size curve formed between the second circular ring and the first circular ring through the space position of the second circular ring;
A welding current correction module for correcting current when welding Exceeding a set maximum welding current/>When welding correction current/>Adjusted to the welding maximum current/>Welding initial current/>Adjusted to/>; When welding correction current/>Exceeding a set maximum welding current/>And/>Below a set welding minimum current/>When welding initial current/>Adjusted to welding minimum current/>And welding correction current/>Adjusted to the welding maximum current/>。
(3) Compared with the prior art, the invention has the beneficial effects that:
Obtaining a contact gap curve by obtaining effective welding time of a welder for initially welding the symmetrical shell plates, thereby obtaining a current contact gap approximately according to the welding progress, and intelligently adjusting current so as to synchronize the welding progress of the welder; when the welding progress is kept synchronous, the symmetrical shell plate dismantling and hoisting conditions or the transverse positioning blocks among the shell plates can be synchronously dismantled, and the welding period is saved.
Drawings
FIG. 1 is a block diagram of a method of welding a spherical pressure tank according to embodiment 1 of the present invention;
FIG. 2 is a schematic diagram of the spherical tank structure in the method for welding the spherical pressure tank according to embodiment 1 of the present invention;
FIG. 3 is a schematic plan view showing the distribution of the welder positions in the circumferential weld welding process in the spherical pressure tank welding method of example 1 of the present invention;
1-an upper pole belt; 2-upper frigid zone; 3-heating the belt; 4-equatorial belt; 5-lower temperature zone; 6-lower frigid zone; 7-a lower pole belt; 8-connecting ribs; 9-supporting legs; 10-shell plate; 11-welder; 12-a transverse positioning block.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Before the example, the application scenario of the present invention needs to be described, the welding workload of the spherical tank is increased, taking a spherical tank with 4000 cubes of volume in a petrochemical plant as an example, the thickness of a shell plate is 40mm, 12 column legs are installed around the periphery of the spherical tank main body, 12 welders are arranged by a constructor to weld synchronously in a symmetrical mode, the workload is counted as 637 meters of the length of a welding seam, the construction period of the welding outside is about 20 days, the construction period of the welding inside is about 10 days, and the total construction period is about 30 days. For 12 welders with abundant experience, the method of ensuring that all welders are approximately consistent in the trial welding process, such as swing welding, is adopted, and from the appearance result after welding, the weld joint is required to be uniform in width, the allowance Gao Pingzheng is uniform, and no air holes and cracks are allowed on the surface of the weld joint; meanwhile, the welding wave on the surface of the welding seam is uniform, the depth of undercut on two sides of the welding seam is less than 0.5mm, obvious concave-convex phenomenon is avoided at the joint of the welding seam, and obvious weld flash is avoided on the surface of the welding seam. When welding spherical tanks in the same batch, the welder uses welding rods in the same batch, and the welding parameters mainly comprise the same settings of welding current and the like, so that 12 welders can realize synchronous welding. In particular, when the girth is welded, 12 welders weld synchronously in a symmetrical mode, because positioning blocks are used between the positioning belts to be positioned and fixed through welding spots, the positioning blocks for blocking the girth are required to be removed along with the process of welding the girth. The spherical tank is formed by splicing more than 20 shell plates, and the assembly error exists in the hoisting splicing process, so long as the assembly error in the threshold range does not affect the use. For example, the contact gap of the shell plates between adjacent bit bands is 3.8mm somewhere, and the contact gap of the shell plates on the symmetrical side is 2.1mm, and the larger the contact gap is, more molten metal is needed to be filled, so that the welding time of a welder is prolonged, and the welding speed is reduced. Most desirably, the contact gaps between the shells are substantially uniform, so that all welders can weld substantially simultaneously under the same welding parameters; however, if the contact gaps are inconsistent, partial welders with small contact gaps will weld faster, and when they need to remove the positioning blocks, they need to wait for the slower welders to finish welding to the symmetrical positioning blocks, so that the welding period of the girth depends on the slowest welders.
Example 1: as shown in fig. 1, the present embodiment provides a spherical pressure tank welding method, which includes:
S1, as shown in FIG. 2, dividing a shell plate of a spherical tank into different zones according to splicing positions, wherein the zones comprise an upper polar zone 1, an upper cold zone 2, an upper warm zone 3, an equatorial zone 4, a lower warm zone 5, a lower cold zone 6 and a lower polar zone 7; the same position belt consists of equally-divided shells with the same shape, the welding seams connected between the shells of the same position belt are marked as longitudinal seams, the welding seams connected between the shells of different position belts are marked as circumferential seams, and the longitudinal seams connected between the shells of different position belts are staggered; the spherical tank in the example is a mixed spherical tank, the equatorial belt 4, the upper temperate zone 3 and the lower temperate zone 5 are designed in orange-petal type, and the upper cold zone 2, the upper polar zone 1, the lower cold zone 6 and the lower polar zone 7 are designed in football type; the purpose of the staggered longitudinal seam distribution is to prevent weld stresses or imperfections from being transmitted along the longer contact gap and reducing the pressure strength of the spherical tank.
S2, splicing the shells corresponding to the equatorial strips 4, reserving contact gaps of longitudinal joints between the shells, overlapping the longitudinal positioning blocks between the shells, firmly welding the longitudinal positioning blocks by welding and fixing the adjacent shells, and completing the positioning of the shells of the equatorial strips 4; the supporting legs 9 are erected, connecting ribs 8 are fixed between the supporting legs 9, and a round plane upper opening formed between the upper ends of the supporting legs 9 is arranged to support the outer side face of the equatorial belt 4; hoisting the equatorial belt 4 to an opening on a circular plane formed between the supporting legs 9, and adjusting the circle center of the equatorial belt 4 to be placed to coincide with the circle center of the opening on the circular plane; welding longitudinal seams among the shells of the equatorial belt 4, and firmly welding and fixing the supporting legs 9 and the shells of the equatorial belt 4; the shell plates are spliced to achieve the correct splicing position by positioning or hoisting, the positioning blocks comprise transverse positioning blocks or longitudinal positioning blocks which are positioned in time, and the positioning blocks can be metal blocks or metal strips with certain widths, so that the two shell plates can be preliminarily fixed to prevent displacement during formal welding.
S3, splicing the shell plates corresponding to the upper temperature zone 3, reserving contact gaps of longitudinal joints between the shell plates, taking the longitudinal positioning blocks to lap the shell plates, firmly welding the longitudinal positioning blocks through welding points and fixing the adjacent shell plates, and completing the positioning of the shell plates of the upper temperature zone 3; hoisting the upper temperature zone 3 to the upper side of the equatorial belt 4 for splicing, reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks 12 along the circular seam, and firmly welding and fixing adjacent shell plates between the upper temperature zone 3 and the equatorial belt 4 through welding spots; welding longitudinal seams among the shells of the upper temperature belt 3, and welding circumferential seams among the shells of the upper temperature belt 3 and the equatorial belt 4;
S4, splicing the shell plates corresponding to the upper cold zone 2, reserving contact gaps of longitudinal joints between the shell plates, taking the longitudinal positioning blocks to lap the shell plates, firmly welding the longitudinal positioning blocks through welding points and fixing the adjacent shell plates, and completing the positioning of the shell plates of the upper cold zone 2; hoisting the upper cold zone 2 to the upper temperature zone 3, splicing and reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks 12 along the circular seam, and firmly welding and fixing adjacent shell plates between the upper cold zone 2 and the upper temperature zone 3 through welding spots; welding longitudinal seams among the shells of the upper cold zone 2, and welding circumferential seams between the shells of the upper cold zone 2 and the upper warm zone 3;
s5, splicing the corresponding shell plates of the upper pole belt 1, reserving contact gaps of longitudinal joints between the shell plates, taking the longitudinal positioning blocks to lap the shell plates, firmly welding the longitudinal positioning blocks through welding points and fixing the adjacent shell plates, and completing the positioning of the shell plates of the upper pole belt 1; hoisting the upper polar belt 1 to the upper cold belt 2, splicing and reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks 12 along the circular seam, and firmly welding and fixing adjacent shell plates between the upper polar belt 1 and the upper cold belt 2 through welding spots; welding longitudinal seams among the shell plates of the upper polar band 1, and welding circumferential seams between the shell plates of the upper polar band 1 and the upper cold band 2;
S6, symmetrically completing welding of the lower temperate zone 5 and the equatorial zone 4 according to a welding method of the upper temperate zone 3, symmetrically completing welding of the lower cold zone 6 and the lower temperate zone 5 according to a welding method of the upper cold zone 2, and symmetrically completing welding of the lower polar zone 7 and the lower cold zone 6 according to a welding method of the upper polar zone 1; after the welding of the outer slope of the outer side of the spherical tank is finished, the inner side of the spherical tank is back-ground and subjected to nondestructive flaw detection, and then an inner groove of the inner side of the spherical tank is welded; after the welding of the outer slope is finished, when the contact gap of the shell plate at the inner side is welded, molten irregular metal liquid is filled into the inner slope, and impurity fragments generated in the welding process of the outer slope are attached to the inner slope at high temperature, so that the inner slope is required to be back-gouged to have welding conditions.
The girth welding method between the bit bands comprises the following steps: the welder 11 is evenly distributed around the outer side of the shell plate 10 forming the circular seam for welding construction, and the initial welding voltage is setAnd welding initiation current/>All welders 11 strike arcs from the shell plates 10 at symmetrical positions, when all welders 11 weld to adjacent shell plates 10 and the transverse positioning blocks 12 are required to be removed or the hoisting conditions of the welded shell plates are removed, arc striking is carried out, the consumption amount of welding rods in the welding process of the welders 11 is counted, and effective welding time is obtained according to the consumption amount of the welding rods; according to the effective welding time sequence counted by the welder 11 in sequence, mapping to an average width sequence of the contact gap in the welding process, and according to the width sequence fitting, generating a contact plane where the two side position bands of the contact gap are positioned; solving a space distance curve between two side bit bands according to the width sequence and the contact plane to obtain a contact gap size curve, and finding a minimum gap value/> on the contact gap size curve; When the current transverse positioning block 12 is removed and the next section of contact gap is welded, predicting the current contact gap of the welder 11 according to the contact gap size curve, and according to the current contact gap and the minimum gap value/>Multiple correction welding initiation current/>Obtaining welding correction current/>. In this embodiment, the number of welders is at least 6, and a spherical tank with 4000 cubes is equipped with 12 welders to work simultaneously, so that each welder needs to dismantle the lateral positioning blocks 12 on the outer side of the shell plate or remove the hoisting condition of the welded shell plate, and the symmetrical lateral positioning blocks 12 are required to be dismantled or the hoisting condition is removed simultaneously, otherwise, uneven stress on the welded weld joint can lead to larger damage of the welded joint, the synchronism of the welding engineering can lead the welded weld joint to be stressed uniformly after the positioning blocks are dismantled or the hoisting condition of the welded shell plate is removed, and the construction period can be saved. When the position is regulated by hoisting, it is difficult to ensure that the sizes of the contact gaps are completely consistent, when a contact gap error exists, the larger the contact gap is, the more welding rods are consumed, and the longer the welding time is, under the condition that the initial welding parameters are approximately consistent, the effective welding time is in direct proportion to the number of the used welding rods, and the contact gaps are estimated through the approximate direct proportion relation between the contact gaps and the welding time, for example, the corresponding width sequence distribution of the contact gaps is [1.5,1.8, 1.2, 1.0, 1.1, 1.3, 1.5, 1.4, 1.3, 1.1, 1.0 and 0.9], and the specific sizes of the contact gaps, for example, the first element of the width sequence is 1.5 units, only the relative values of the contact gaps are needed to be obtained. The contact gap is formed by the profile side surfaces of the adjacent bit bands, the side surfaces are approximately one contact plane, when 12 welders can obtain the contact gap at 12 position points which are uniformly distributed, one contact plane is used as a reference plane, the other contact plane can be fitted, and after the space positions of the two contact planes are determined, the size curve of the contact gap between the two contact planes can be obtained. The contact gap between the next section of shell plates is obtained through the current position of the welder 12, the welding speed of the welder at the position with a larger welding line is improved through improving the current, and the welding current is improved to be approximately in direct proportion to the welding speed, so that the welding speed of the welder at the position with a smaller welding line is kept at approximately consistent construction speed.
Further, the method for generating the contact plane where the bit bands at two sides of the contact gap are located according to the width sequence fitting comprises the following steps:
Setting a fixed first plane as a contact plane at one side of a contact gap, marking the other contact plane as a second plane, marking the annular projection of the bit zone on the first plane as a first annular, marking the annular projection of the bit zone on the second plane as a second annular, and enabling the first annular and the second annular to be non-parallel and enabling the circle centers of the first annular and the second annular to have no concentric relation; the center of the first ring is taken as the origin of coordinates, and the first ring is arranged at The plane is provided with an included angle vector of the second annular center relative to the first annular center asWherein/>、/>And/>Respectively the =/>, of the second ring relative to the first ringAxis,/>Shaft sum/>The Euler angle of the shaft rotation, and the translation vector of the second annular center of a circle relative to the first annular center of a circle is/>; The width sequence formula corresponding to the contact gap is set as:
；
Wherein the method comprises the steps of Is the vector of any point on the second ring,/>Is/>Vectors of perpendicular projection points of the corresponding points on the first ring; the width sequence is the vertical distance from the welding position on the second ring to the first ring, and the error function of the width sequence is set as follows:
；
Wherein the method comprises the steps of Is the/>, in the width sequenceElement,/>Is the number of elements in the width sequence,/>Is the first in the width sequenceA vector corresponding to a point of the element on the first ring; bringing the width sequence into the error function/>And using gradient descent algorithm to fit to obtain included angle vector/>And translation vector/>Thereby obtaining the spatial position of the second ring; the size curve of the contact gap formed between the second circular ring and the first circular ring is obtained through the space position of the second circular ring. Calculating error function as/>, by gradient descent algorithmIn particular by solving an error function/>From the parameter at 0 according to the derivative and the error function/>, on both sides of this parameterPositive and negative values of the derivative to find the error function as/>Is a minimum value of (2). And carrying the parameter equation into a corresponding width sequence of a plurality of welders to solve to obtain the spatial position of the second plane.
Further, the method further comprises:
When welding correcting current Exceeding a set maximum welding current/>When welding correction current/>Adjusted to the welding maximum current/>Welding initial current/>Adjusted to/>; When welding correction current/>Exceeding a set maximum welding current/>And/>Below a set welding minimum current/>When welding initial current/>Adjusted to welding minimum current/>And welding correction current/>Adjusted to the welding maximum current/>. The best current regulation is to increase the welding current at the slower welding point, i.e. the point with larger contact gap, but the welding current may exceed the set welding maximum current/>Therefore, welding correction current/>, is requiredAdjusted to the welding maximum current/>Welding initial currentThe welding current is reduced, so that the construction efficiency can be sacrificed, the welding quality can be improved, and the excessive welding current is prevented from causing the over-burning and penetration of the welding line. While when the initial current of welding needs to be regulated and/>Below a set welding minimum current/>The weld joint at a part position needs to reduce welding current, but the welding current cannot be lower than the set welding minimum current/>In this case, slag inclusion or lack of fusion, which would otherwise reduce welding strength, is prevented from occurring due to failure in welding. Welding initiation current at this time/>And welding correction current/>All are limited by the welding current threshold, and although the synchronicity of some welding constructions is sacrificed, the welding quality in the welding process can be improved, and the comprehensive performance of the synchronicity of the welding construction and the welding quality is pursued.
Further, the method further comprises:
And after the welding correction current is calculated and validated, counting the number of welding rods consumed by a welder 11 during the next section of shell plate welding to obtain the actual welding time, obtaining a welding line corresponding to the abnormal period of the actual welding time through a Z-score method, and performing nondestructive inspection on the welding line corresponding to the abnormal period of the actual welding time in advance. When the welding time is basically synchronous, if the actual welding time of a certain welder 11 is abnormal, the welding instability of the welder 11 during the description needs to be detected in advance, and particularly when the welding line is in a multi-layer welding layer, the welding defect can be found in advance.
Further, the method further comprises:
When the welders 11 are uniformly distributed around the outer side of the shell plate 10 forming the circular seam for welding construction, the welding seam corresponding to each shell plate is divided into equal-length welding sections, and the welding is performed in the whole welding direction of the shell plate, wherein the welding direction of each welding section is opposite to the whole welding direction.
Further, the method further comprises:
before shell plates of the spherical tank are welded, removing dirt on the surface of the spherical shell within the range of at least 15mm on two sides of a welding groove of the shell plates; the shell plate welding groove comprises an outer groove formed on the outer side of the shell plate and an inner groove formed on the inner side of the shell plate, wherein an included angle of the outer groove is 50-60 degrees, an included angle of the inner groove is 55-65 degrees, the depth of the outer groove is 55-65% of the wall thickness, and the depth of the inner groove is 30-45% of the wall thickness. All welding seams of the spherical tank adopt double V-shaped grooves, a large groove of the welding seam of the spherical tank is arranged on the outer side, and a small groove is arranged on the inner side.
Further, the method further comprises:
When splicing the shell plates or the bit bands, reserving a contact gap of a welding line to be 2-4 mm; after splicing between the shell plates or the positioning strips is completed, the adjacent shell plates which are not welded and fixed are fixed through welding transverse positioning blocks or longitudinal positioning blocks, and the length of the spot welding seam of the transverse positioning blocks or the longitudinal positioning blocks, which is welded on the shell plates, is at least 10mm.
Further, the method further comprises:
Filling a contact gap between the shell plates or the bit bands through at least two layers of welding layers, wherein each layer of welding layer is 2.5-3.5 mm, and welding heads of each layer are staggered by at least 50mm due to arc starting; and after each layer of welding layer is welded, polishing the uneven welding heads caused by arcing of each layer of welding layer to enable the welding layer to be kept flat.
Further, the method for back chipping and polishing the inner side of the spherical tank comprises the following steps:
Trimming the inner side of the welding seam of the shell plate into a U-shaped gouging groove through a carbon arc gouging machine, wherein the gouging groove depth is kept consistent with the gouging width, the gouging groove depth is 5-6 mm, and the gouging width is 12-16 mm; the gouges are polished to make the surface smooth and carburized free and remove dirt in the gouges.
Example 2: based on the same inventive concept, as shown in fig. 2, the present embodiment further provides a spherical pressure tank welding system, which is applied to the spherical pressure tank welding method, and the system includes:
The contact curve estimating module is used for setting a fixed first plane as a contact plane at one side of the contact gap, marking the other contact plane as a second plane, marking the annular projection of the bit zone on the first plane as a first annular, marking the annular projection of the bit zone on the second plane as a second annular, and enabling the first annular and the second annular to be non-parallel and enabling the circle centers of the first annular and the second annular to have no concentric relation; the center of the first ring is taken as the origin of coordinates, and the first ring is arranged at The plane is provided with an included angle vector of the second annular center relative to the first annular center as/>Wherein/>、/>And/>The/>, respectively, of the second ring relative to the first ringAxis,/>Shaft sum/>The Euler angle of the shaft rotation, and the translation vector of the second annular center of a circle relative to the first annular center of a circle is/>; The width sequence formula corresponding to the contact gap is set as:
；
Wherein the method comprises the steps of Is the vector of any point on the second ring,/>Is/>Vectors of perpendicular projection points of the corresponding points on the first ring; the width sequence is the vertical distance from the welding position on the second ring to the first ring, and the error function of the width sequence is set as follows:
；
Wherein the method comprises the steps of Is the/>, in the width sequenceElement,/>Is the number of elements in the width sequence,/>Is the first in the width sequenceA vector corresponding to a point of the element on the first ring; bringing the width sequence into the error function/>And using gradient descent algorithm to fit to obtain included angle vector/>And translation vector/>Thereby obtaining the spatial position of the second ring; obtaining a contact gap size curve formed between the second circular ring and the first circular ring through the space position of the second circular ring;
A welding current correction module for correcting current when welding Exceeding a set maximum welding current/>When welding correction current/>Adjusted to the welding maximum current/>Welding initial current/>Adjusted to/>; When welding correction current/>Exceeding a set maximum welding current/>And/>Below a set welding minimum current/>When welding initial current/>Adjusted to welding minimum current/>And welding correction current/>Adjusted to the welding maximum current/>。
It should be noted that, regarding the system in the above embodiment, the specific manner in which the respective modules perform the operations has been described in detail in the embodiment regarding the method, and will not be described in detail herein.
Finally, it should be noted that: although the present invention has been described with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments described, or equivalents may be substituted for elements thereof, and any modifications, equivalents, improvements and changes may be made without departing from the spirit and principles of the present invention.
Claims (10)
1. A method of welding a spherical pressure tank, the method comprising:
Dividing the shell plate of the spherical tank into different bit zones according to splicing positions, wherein the bit zones comprise an upper polar zone (1), an upper cold zone (2), an upper warm zone (3), an equatorial zone (4), a lower warm zone (5), a lower cold zone (6) and a lower polar zone (7); the same position belt consists of equally-divided shells with the same shape, the welding seams connected between the shells of the same position belt are marked as longitudinal seams, the welding seams connected between the shells of different position belts are marked as circumferential seams, and the longitudinal seams connected between the shells of different position belts are staggered;
Splicing shells corresponding to the equatorial strips (4), reserving contact gaps of longitudinal joints between the shells, overlapping longitudinal positioning blocks between the shells, firmly welding the longitudinal positioning blocks by welding and fixing adjacent shells, and completing the positioning of the shells of the equatorial strips (4); the method comprises the steps of erecting supporting legs (9), fixing connecting ribs (8) between the supporting legs (9), and arranging an upper opening of a circular plane formed between the upper ends of the supporting legs (9) to support the outer side face of an equatorial belt (4); hoisting the equatorial belt (4) to an opening on a circular plane formed between the supporting legs (9), and adjusting the circle center of the equatorial belt (4) to be placed to coincide with the circle center of the opening on the circular plane; welding longitudinal seams among the shells of the equatorial belt (4), and firmly welding and fixing the supporting legs (9) and the shells of the equatorial belt (4);
Splicing the shell plates corresponding to the upper temperature zone (3), reserving a contact gap of a longitudinal seam between the shell plates, overlapping the longitudinal positioning blocks between the shell plates, firmly welding the longitudinal positioning blocks by welding and fixing the adjacent shell plates, and completing the positioning of the shell plates of the upper temperature zone (3); hoisting the upper temperature zone (3) to the upper side of the equatorial zone (4) for splicing, reserving a contact gap of a circular seam, maintaining a hoisting state, taking transverse positioning blocks (12) uniformly distributed along the circular seam, and firmly welding and fixing adjacent shells between the upper temperature zone (3) and the shells of the equatorial zone (4) through welding spots; welding longitudinal seams among the shells of the upper temperature belt (3), and welding circumferential seams among the shells of the upper temperature belt (3) and the equatorial belt (4);
Splicing the corresponding shell plates of the upper cold strip (2), reserving a contact gap of a longitudinal seam between the shell plates, overlapping the longitudinal positioning blocks between the shell plates, firmly welding the longitudinal positioning blocks by welding and fixing the adjacent shell plates, and completing the positioning of the shell plates of the upper cold strip (2); hoisting the upper cold zone (2) to the upper temperature zone (3), splicing and reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks (12) along the circular seam, and firmly welding and fixing adjacent shell plates between the upper cold zone (2) and the shell plates of the upper temperature zone (3) through welding spots; welding longitudinal seams among the shells of the upper cold zone (2), and welding circumferential seams between the shells of the upper cold zone (2) and the upper warm zone (3);
Splicing the corresponding shell plates of the upper pole belt (1), reserving a contact gap of a longitudinal seam between the shell plates, taking a longitudinal positioning block to be overlapped between the shell plates, firmly welding the longitudinal positioning block by welding and fixing the adjacent shell plates, and completing the positioning of the shell plates of the upper pole belt (1); hoisting the upper polar band (1) to the upper cold band (2), splicing and reserving a contact gap of a circular seam, maintaining a hoisting state, uniformly distributing transverse positioning blocks (12) along the circular seam, and firmly welding and fixing adjacent shell plates between the upper polar band (1) and the shell plates of the upper cold band (2) through welding spots; welding a longitudinal seam between the shell plates of the upper polar band (1), and welding a circumferential seam between the upper polar band (1) and the shell plates of the upper cold band (2);
Welding of the lower temperate zone (5) and the equatorial zone (4) is symmetrically completed according to a welding method of the upper temperate zone (3), welding of the lower cold zone (6) and the lower temperate zone (5) is symmetrically completed according to a welding method of the upper cold zone (2), and welding of the lower polar zone (7) and the lower cold zone (6) is symmetrically completed according to a welding method of the upper polar zone (1); after the welding of the outer slope of the outer side of the spherical tank is finished, the inner side of the spherical tank is back-ground and subjected to nondestructive flaw detection, and then an inner groove of the inner side of the spherical tank is welded;
The girth welding method between the bit bands comprises the following steps: welding workers (11) are uniformly distributed around the outer side of a shell plate (10) forming a circular seam to perform welding construction, and the initial welding voltage is set And welding initiation current/>All welders (11) strike arcs from the shell plates (10) at symmetrical positions, arc is received when all welders (11) are welded to adjacent shell plates (10) and the transverse positioning blocks (12) are required to be removed or the hoisting condition of the welded shell plates is removed, the consumption number of welding rods in the welding process of the welders (11) is counted, and effective welding time is obtained according to the consumption number of the welding rods; according to the effective welding time sequence counted by a welder (11), mapping to an average width sequence of the contact gap in the welding process, and fitting according to the width sequence to generate a contact plane where the bit bands at two sides of the contact gap are positioned; solving a space distance curve between two side bit bands according to the width sequence and the contact plane to obtain a contact gap size curve, and finding a minimum gap value/> on the contact gap size curve; When the current transverse positioning block (12) is removed and the next section of contact gap is welded, predicting the current contact gap of a welder (11) according to the size curve of the contact gap, and determining the minimum gap value/>, according to the current contact gapMultiple correction welding initiation current/>Obtaining welding correction current/>。
2. The method of welding a spherical pressure tank of claim 1, wherein the step of generating a contact plane for the bit strips on both sides of the contact gap based on the width sequence fit comprises:
Setting a fixed first plane as a contact plane at one side of a contact gap, marking the other contact plane as a second plane, marking the annular projection of the bit zone on the first plane as a first annular, marking the annular projection of the bit zone on the second plane as a second annular, and enabling the first annular and the second annular to be non-parallel and enabling the circle centers of the first annular and the second annular to have no concentric relation; the center of the first ring is taken as the origin of coordinates, and the first ring is arranged at The plane is provided with an included angle vector of the second annular center relative to the first annular center as/>Wherein/>、/>And/>The/>, respectively, of the second ring relative to the first ringAxis,/>Shaft sum/>The Euler angle of the shaft rotation, and the translation vector of the second annular center of a circle relative to the first annular center of a circle is/>; The width sequence formula corresponding to the contact gap is set as:
；
Wherein the method comprises the steps of Is the vector of any point on the second ring,/>Is/>Vectors of perpendicular projection points of the corresponding points on the first ring; the width sequence is the vertical distance from the welding position on the second ring to the first ring, and the error function of the width sequence is set as follows:
；
Wherein the method comprises the steps of Is the/>, in the width sequenceElement,/>Is the number of elements in the width sequence,/>Is the/>, in the width sequenceA vector corresponding to a point of the element on the first ring; bringing the width sequence into the error function/>And using gradient descent algorithm to fit to obtain included angle vector/>And translation vector/>Thereby obtaining the spatial position of the second ring; the size curve of the contact gap formed between the second circular ring and the first circular ring is obtained through the space position of the second circular ring.
3. The spherical pressure tank welding method of claim 1, further comprising:
When welding correcting current Exceeding a set maximum welding current/>When welding correction current/>Adjusted to the welding maximum current/>Welding initial current/>Adjusted to/>; When welding correction current/>Exceeding a set maximum welding current/>And/>Below a set welding minimum current/>When welding initial current/>Adjusted to welding minimum current/>And welding correction current/>Adjusted to the welding maximum current/>。
4. A spherical pressure tank welding method as defined in claim 3, further comprising:
And after the welding correction current is calculated and validated, counting the number of welding rods consumed by a welder (11) during the next section of shell plate welding to obtain the actual welding time, obtaining a welding line corresponding to the abnormal period of the actual welding time through a Z-score method, and carrying out nondestructive inspection on the welding line corresponding to the abnormal period of the actual welding time in advance.
5. The spherical pressure tank welding method of claim 4, further comprising:
When welding construction is carried out by the welders (11) around the outer sides of the shell plates (10) forming the circular seams in an even distribution mode, the welding seams corresponding to each shell plate are divided into equal-length welding sections, and the welding sections are subjected to welding withdrawal in the overall welding direction of the shell plates, wherein the welding withdrawal direction of each welding section is opposite to the overall welding direction.
6. The spherical pressure tank welding method of claim 1, further comprising:
before shell plates of the spherical tank are welded, removing dirt on the surface of the spherical shell within the range of at least 15mm on two sides of a welding groove of the shell plates; the shell plate welding groove comprises an outer groove formed on the outer side of the shell plate and an inner groove formed on the inner side of the shell plate, wherein an included angle of the outer groove is 50-60 degrees, an included angle of the inner groove is 55-65 degrees, the depth of the outer groove is 55-65% of the wall thickness, and the depth of the inner groove is 30-45% of the wall thickness.
7. The spherical pressure tank welding method of claim 1, further comprising:
When splicing the shell plates or the bit bands, reserving a contact gap of a welding line to be 2-4 mm; after splicing between the shell plates or the positioning strips is completed, the adjacent shell plates which are not welded and fixed are fixed through welding transverse positioning blocks or longitudinal positioning blocks, and the length of the spot welding seam of the transverse positioning blocks or the longitudinal positioning blocks, which is welded on the shell plates, is at least 10mm.
8. The spherical pressure tank welding method of claim 1, further comprising:
Filling a contact gap between the shell plates or the bit bands through at least two layers of welding layers, wherein each layer of welding layer is 2.5-3.5 mm, and welding heads of each layer are staggered by at least 50mm due to arc starting; and after each layer of welding layer is welded, polishing the uneven welding heads caused by arcing of each layer of welding layer to enable the welding layer to be kept flat.
9. The welding method of a spherical pressure tank according to claim 1, wherein the method of back chipping and polishing the inner side of the spherical tank comprises:
Trimming the inner side of the welding seam of the shell plate into a U-shaped gouging groove through a carbon arc gouging machine, wherein the gouging groove depth is kept consistent with the gouging width, the gouging groove depth is 5-6 mm, and the gouging width is 12-16 mm; the gouges are polished to make the surface smooth and carburized free and remove dirt in the gouges.
10. Spherical pressure tank welding system, applied to the spherical pressure tank welding method according to any one of claims 1 to 9, characterized in that it comprises:
The contact curve estimating module is used for setting a fixed first plane as a contact plane at one side of the contact gap, marking the other contact plane as a second plane, marking the annular projection of the bit zone on the first plane as a first annular, marking the annular projection of the bit zone on the second plane as a second annular, and enabling the first annular and the second annular to be non-parallel and enabling the circle centers of the first annular and the second annular to have no concentric relation; the center of the first ring is taken as the origin of coordinates, and the first ring is arranged at The plane is provided with an included angle vector of the second annular center relative to the first annular center asWherein/>、/>And/>The/>, respectively, of the second ring relative to the first ringAxis,/>Shaft sum/>The Euler angle of the shaft rotation, and the translation vector of the second annular center of a circle relative to the first annular center of a circle is/>; The width sequence formula corresponding to the contact gap is set as:
；
Wherein the method comprises the steps of Is the vector of any point on the second ring,/>Is/>Vectors of perpendicular projection points of the corresponding points on the first ring; the width sequence is the vertical distance from the welding position on the second ring to the first ring, and the error function of the width sequence is set as follows:
；
Wherein the method comprises the steps of Is the/>, in the width sequenceElement,/>Is the number of elements in the width sequence,/>Is the/>, in the width sequenceA vector corresponding to a point of the element on the first ring; bringing the width sequence into the error function/>And using gradient descent algorithm to fit to obtain included angle vector/>And translation vector/>Thereby obtaining the spatial position of the second ring; obtaining a contact gap size curve formed between the second circular ring and the first circular ring through the space position of the second circular ring;
A welding current correction module for correcting current when welding Exceeding a set maximum welding current/>When welding correction current/>Adjusted to the welding maximum current/>Welding initial current/>Adjusted to/>; When welding correcting currentExceeding a set maximum welding current/>And/>Below a set welding minimum current/>When welding initial current/>Adjusted to welding minimum current/>And welding correction current/>Adjusted to the welding maximum current/>。
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| CN104096954A (en) * | 2014-06-26 | 2014-10-15 | 中建一局集团安装工程有限公司 | Double two-sided synchronous tungsten electrode high-frequency pulse argon arc welding butt welding method |
| CN206393120U (en) * | 2016-12-27 | 2017-08-11 | 四川川锅锅炉有限责任公司 | A kind of many people of refuse furnace tube panel are while welding frock |
| CN108071234A (en) * | 2017-12-18 | 2018-05-25 | 中国冶集团有限公司 | A kind of assemble method of large size Hydrogenation reactor spherical tank |
| CN110356512A (en) * | 2019-07-22 | 2019-10-22 | 浙江新乐造船股份有限公司 | A kind of liquefied natural gas boat-carrying binary storage tank and its manufacturing method |
| CN110902173A (en) * | 2019-11-06 | 2020-03-24 | 中国化学工程第六建设有限公司 | Large thick-wall stainless steel ball tank and assembling and welding method thereof |
| CN110899920A (en) * | 2019-12-11 | 2020-03-24 | 中车长江车辆有限公司 | Girth welding method for low-alloy steel low-temperature pressure container tank body |
| CN211974263U (en) * | 2020-01-09 | 2020-11-20 | 中建一局集团第二建筑有限公司 | Large-scale wine storage tank installation operation platform |
| CN111673236A (en) * | 2020-07-22 | 2020-09-18 | 徐州华恒机器人系统有限公司 | Cylinder type outer circular seam welding production line |
| CN113266757A (en) * | 2021-05-13 | 2021-08-17 | 中铁十八局集团有限公司 | Thermal angle protection inversion construction method for LNG (liquefied Natural gas) bimetallic full-capacity storage tank |
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