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CN103447676A - Pipeline flash butt-welding welding seam plasma slag clearing and heat treatment machine - Google Patents

Pipeline flash butt-welding welding seam plasma slag clearing and heat treatment machine Download PDF

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CN103447676A
CN103447676A CN2013103871724A CN201310387172A CN103447676A CN 103447676 A CN103447676 A CN 103447676A CN 2013103871724 A CN2013103871724 A CN 2013103871724A CN 201310387172 A CN201310387172 A CN 201310387172A CN 103447676 A CN103447676 A CN 103447676A
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heat treatment
pipe
plasma
slag removal
crawling
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CN103447676B (en
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高世一
陈和兴
李海权
郭春富
刘正林
房卫萍
易耀勇
郑世达
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Huizhou Huifeng Huifeng Science And Technology Co ltd
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Guangzhou Research Institute of Non Ferrous Metals
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Abstract

一种管道闪光对焊焊缝等离子清渣及热处理机,包括管内爬行定位机构、通过该管内爬行定位机构推动位移及定位的管内焊缝等离子清渣及热处理机构、用于控制管内爬行定位机构和管内焊缝等离子清渣及热处理机构动作的监控单元。本发明的设备柔性好,对不同尺寸管道的适应性强,采用一套设备可对不同管径的管道内部焊缝进行焊缝清渣及热处理,焊缝清渣效果好;本发明在清渣的同时能够对焊缝进行热处理,可明显改善焊缝力学性能,提高焊缝使用寿命;本发明的设备结构紧凑、易实现整机小型化,而且应用范围广,适用于直径范围为219mm~325mm的不同金属材质管道。

Figure 201310387172

A plasma slag removal and heat treatment machine for pipeline flash butt welding, including a crawling positioning mechanism in a pipe, a plasma cleaning and heat treatment mechanism for welding seams in a pipe that is displaced and positioned by the crawling positioning mechanism in a pipe, and a mechanism for controlling the crawling positioning mechanism in a pipe and The monitoring unit for plasma slag cleaning and heat treatment mechanism action in the weld seam in the pipe. The equipment of the present invention has good flexibility and strong adaptability to pipes of different sizes. A set of equipment can be used to perform weld slag removal and heat treatment on the internal welds of pipes with different pipe diameters, and the effect of welding slag removal is good; the present invention is effective in slag removal At the same time, heat treatment can be performed on the weld seam, which can obviously improve the mechanical properties of the weld seam and increase the service life of the weld seam; the equipment of the present invention has a compact structure, is easy to realize the miniaturization of the whole machine, and has a wide range of applications, and is suitable for diameters ranging from 219mm to 325mm different metal pipes.

Figure 201310387172

Description

一种管道闪光对焊焊缝等离子清渣及热处理机A plasma slag cleaning and heat treatment machine for pipeline flash butt welding seam

技术领域 technical field

本发明涉及等离子技术应用于管道闪光对焊技术领域,具体是涉及一种管道闪光对焊管内焊缝等离子清渣及热处理机。 The invention relates to the technical field of plasma technology applied to pipeline flash butt welding, in particular to a plasma slag cleaning and heat treatment machine for internal weld seams of pipeline flash butt welding pipes.

背景技术 Background technique

闪光对焊是一种先进的焊接方法,和传统焊接方法相比,具有如下优势:1、属于固相焊接,不存在熔池,焊接质量高;2、无需添加熔敷金属,焊接接头化学成分与母材相同;3、无需气体保护或渣保护,消除了污染源;4、自动化程度高,不依靠手工焊接技能;5、焊接周期短,焊接效率高。 Flash butt welding is an advanced welding method. Compared with traditional welding methods, it has the following advantages: 1. It belongs to solid phase welding without molten pool and high welding quality; 2. No need to add deposited metal, and the chemical composition of welded joints It is the same as the base metal; 3. No need for gas protection or slag protection, eliminating the source of pollution; 4. High degree of automation, no need to rely on manual welding skills; 5. Short welding cycle and high welding efficiency.

闪光焊接技术虽然有诸多优点,但是闪光焊接技术存在一个极为关键的技术瓶颈,就是焊接后焊缝残渣需要清理。对于小直径长管道,管道内部接头焊缝清理难题表现的尤为突出。闪光焊接焊缝清渣问题成为管道闪光焊接技术推广应用的一个技术壁垒,必须攻克。 Although the flash welding technology has many advantages, there is a very critical technical bottleneck in the flash welding technology, that is, the weld residue needs to be cleaned after welding. For small-diameter long pipelines, the difficulty of cleaning the weld seam of the internal joints of the pipeline is particularly prominent. The problem of flash welding weld slag removal has become a technical barrier to the popularization and application of pipeline flash welding technology and must be overcome.

目前,国内外采用的清渣方法主要有手工打磨法和机械推凸法等。然而,手工打磨法的工人劳动强度大,效率低,且对于小型管道根本无法伸入管内作业。机械推凸法在去除管道焊接接头毛刺时的缺点是对于每个尺寸的管道,都需要一个单独的去毛刺装置,特别是处理小直径管道焊接接头的装置,具有极复杂的结构和高昂的成本。 At present, the slag removal methods used at home and abroad mainly include manual grinding method and mechanical pushing method. Yet the workman's labor intensity of manual polishing method is big, and efficiency is low, and can't stretch into the operation in pipe at all for small pipeline. The disadvantage of the mechanical push-and-convex method when deburring pipe welded joints is that for each size of pipe, a separate deburring device is required, especially for small-diameter pipe welded joints, which has an extremely complicated structure and high cost .

发明内容 Contents of the invention

本发明的目的在于针对上述存在问题和不足,提供一种结构可靠、使用方便灵活,在清除焊缝残渣的同时能够对焊缝进行热处理,能够显著提高管道的焊接质量及使用寿命的管道闪光对焊焊缝等离子清渣及热处理机。 The object of the present invention is to solve the above existing problems and deficiencies, to provide a pipeline flashing pair with reliable structure, convenient and flexible use, which can heat-treat the weld while removing the weld residue, and can significantly improve the welding quality and service life of the pipeline. Weld seam plasma slag cleaning and heat treatment machine.

本发明的技术方案是这样实现的: Technical scheme of the present invention is realized like this:

本发明所述的管道闪光对焊焊缝等离子清渣及热处理机,其特点是包括管内爬行定位机构、通过该管内爬行定位机构推动位移及定位的管内焊缝等离子清渣及热处理机构、用于控制管内爬行定位机构和管内焊缝等离子清渣及热处理机构动作的监控单元。 The plasma slag removal and heat treatment machine for pipeline flash butt welding according to the present invention is characterized in that it includes a crawling positioning mechanism in the pipe, a plasma slag removal and heat treatment mechanism for the welding seam in the pipe that is displaced and positioned by the crawling positioning mechanism in the pipe, and is used for A monitoring unit that controls the movement of the crawling positioning mechanism in the pipe and the plasma slag cleaning and heat treatment mechanism for the weld seam in the pipe.

其中,上述管内爬行定位机构包括车架及安装在车架上的交流电机、行星二级减速器、主动轮、被动轮、齿轮齿条机构、制动电磁铁和行走位移测量机构,其中所述行星二级减速器的动力输入端与交流电机的动力输出端相连接,所述主动轮和齿轮齿条机构分别与行星二级减速器的动力输出端相连接,所述制动电磁铁与齿轮齿条机构相连接,所述行走位移测量机构包括测长编码齿轮和旋转编码器,所述测长编码齿轮与被动轮上设置的齿轮啮合连接,所述旋转编码器的轴端与测长编码齿轮通过键槽配合连接。 Wherein, the above-mentioned crawling positioning mechanism in the tube includes a vehicle frame and an AC motor installed on the vehicle frame, a planetary secondary reducer, a driving wheel, a driven wheel, a rack and pinion mechanism, a brake electromagnet and a travel displacement measuring mechanism, wherein the The power input end of the planetary two-stage reducer is connected with the power output end of the AC motor, the driving wheel and the rack and pinion mechanism are respectively connected with the power output end of the planetary two-stage reducer, and the brake electromagnet is connected with the gear The rack mechanism is connected, and the walking displacement measuring mechanism includes a length-measuring coding gear and a rotary encoder. The gears are connected by a keyway fit.

上述管内焊缝等离子清渣及热处理机构包括用于对管内焊缝进行清渣及热处理的等离子枪、用于调节等离子枪使用位置的三自由度调节机构和用于监测等离子枪清渣状态及焊缝处理效果的单目视觉监测单元。 The above-mentioned plasma slag removal and heat treatment mechanism for the weld seam in the pipe includes a plasma gun for slag removal and heat treatment for the weld seam in the pipe, a three-degree-of-freedom adjustment mechanism for adjusting the position of the plasma gun, and a plasma gun for monitoring the slag removal status and welding. Monocular vision monitoring unit for seam processing effect.

上述三自由度调节机构包括用于带动等离子枪旋转的伺服电机、用于带动等离子枪径向移动的直线电机机构和用于带动等离子枪偏转摆动的双齿轮传导机构,其中所述直线电机机构包括直线电机及与直线电机的传动轴相连接的运动导轨,所述直线电机安装在直线电机套筒内并通过直线电机套筒与伺服电机的传动轴固定连接,所述双齿轮传导机构包括驱动电机、与驱动电机的传动轴相连接的主动齿轮及与主动齿轮啮合连接的被动齿轮,所述双齿轮传导机构和等离子枪分别安装在运动导轨上,且所述等离子枪与被动齿轮固定连接并与外部的离子气及保护气设备和循环冷却水箱相连通。 The above-mentioned three-degree-of-freedom adjustment mechanism includes a servo motor for driving the plasma gun to rotate, a linear motor mechanism for driving the plasma gun to move radially, and a double-gear transmission mechanism for driving the plasma gun to deflect and swing, wherein the linear motor mechanism includes The linear motor and the motion guide rail connected with the transmission shaft of the linear motor, the linear motor is installed in the linear motor sleeve and fixedly connected with the transmission shaft of the servo motor through the linear motor sleeve, and the double gear transmission mechanism includes a drive motor 1. A driving gear connected to the transmission shaft of the drive motor and a passive gear meshed with the driving gear, the double gear transmission mechanism and the plasma gun are respectively installed on the moving guide rail, and the plasma gun is fixedly connected with the driven gear and connected with the The external ion gas and protective gas equipment are connected with the circulating cooling water tank.

为了使本发明的操作人员能够实时并准确地掌握焊缝的清渣及热处理状态,上述单目视觉监测单元包括CCD相机、图像采集卡、环形光源、滤波器和无线发射器,所述无线发射器与监控单元信号连接,所述CCD相机通过支架安装固定在三自由度调节机构上且位于等离子枪的下方。 In order to enable the operator of the present invention to grasp the slag removal and heat treatment status of the weld seam accurately in real time, the above-mentioned monocular vision monitoring unit includes a CCD camera, an image acquisition card, a ring light source, a filter and a wireless transmitter, and the wireless transmitter The CCD camera is connected with the monitoring unit signal, and the CCD camera is installed and fixed on the three-degree-of-freedom adjustment mechanism through a bracket and is located below the plasma gun.

为了使本发明的位置调节方便、准确,本发明还包括有通过监控单元控制动作的管内位置调节机构,所述管内位置调节机构设置在管内爬行定位机构和管内焊缝等离子清渣及热处理机构之间。 In order to make the position adjustment of the present invention convenient and accurate, the present invention also includes an in-pipe position adjustment mechanism controlled by a monitoring unit, and the in-pipe position adjustment mechanism is arranged between the crawling positioning mechanism in the pipe and the plasma slag cleaning and heat treatment mechanism in the pipe. between.

为了使本发明能够满足不同直径管道的需求,上述管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的径向位置进行粗调的丝杆调节机构,该丝杆调节机构由调节丝杆和调节螺母组成且连接在管内爬行定位机构上。 In order to enable the present invention to meet the requirements of pipelines with different diameters, the position adjustment mechanism in the pipe includes a screw adjustment mechanism for roughly adjusting the radial position of the welding seam plasma slag removal and heat treatment mechanism in the pipe. The screw adjustment mechanism is adjusted by The screw rod and the adjusting nut are composed and connected to the crawling positioning mechanism in the pipe.

为了使本发明能够保证管道轴线与等离子枪旋转的轴线重合,从而实现精确调心定位,上述管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的径向位置进行精调的变径调心机构,该变径调心机构包括连接轴及连接轴两端各设置的一组气动调心定位机构,所述各组气动调心定位机构分别由连接套、固定在连接套上且按圆周均匀排布的三个气缸及各气缸的活塞杆外端连接的一个球形压轮组成。 In order to make the present invention ensure that the axis of the pipeline coincides with the axis of rotation of the plasma gun, so as to achieve precise self-alignment and positioning, the above-mentioned position adjustment mechanism in the pipe includes a changer for fine adjustment of the radial position of the plasma slag removal and heat treatment mechanism in the pipe. Diameter centering mechanism, the variable diameter centering mechanism includes a connecting shaft and a set of pneumatic centering positioning mechanisms respectively provided at both ends of the connecting shaft, each group of pneumatic centering positioning mechanisms is fixed on the connecting sleeve by the connecting sleeve and It consists of three cylinders evenly arranged on the circumference and a spherical pressure wheel connected to the outer end of the piston rod of each cylinder.

为了使本发明能够实现等离子枪的轴向微调功能,从而提高等离子枪使用位置的精度,上述管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的轴向位置进行微调的轴向位移微调机构,该轴向位移微调机构由伺服气缸、电磁换向阀、压力传感器、位置传感器和控制器组成。 In order to enable the present invention to realize the axial fine-tuning function of the plasma gun, thereby improving the accuracy of the use position of the plasma gun, the above-mentioned in-tube position adjustment mechanism includes an axial axis for fine-tuning the axial position of the plasma slag cleaning and heat treatment mechanism in the tube. A displacement fine-tuning mechanism, the axial displacement fine-tuning mechanism is composed of a servo cylinder, an electromagnetic reversing valve, a pressure sensor, a position sensor and a controller.

为了使本发明的操作及控制方便,且自动化程度高,上述监控单元包括机载控制单元和管外监控单元,所述机载控制单元包括PLC控制器及与PLC控制器电连接的无线数据传输器,所述管外监控单元包括图像监视器、无线收发信号单元、离子气及保护气控制单元、循环冷却水箱控制单元、焊缝图像算法处理单元、管内爬行定位机构位移控制单元和等离子枪位姿调节控制单元,所述无线数据传输器与收发信号单元信号连接。 In order to make the operation and control of the present invention convenient, and the degree of automation is high, the above-mentioned monitoring unit includes an on-board control unit and an external monitoring unit, and the on-board control unit includes a PLC controller and a wireless data transmission device electrically connected to the PLC controller. The monitoring unit outside the tube includes an image monitor, a wireless transceiver unit, an ion gas and shielding gas control unit, a circulating cooling water tank control unit, a weld seam image algorithm processing unit, a displacement control unit of the crawling positioning mechanism in the tube, and a plasma gun position an attitude adjustment control unit, and the wireless data transmitter is signal-connected with the sending and receiving signal unit.

本发明与现有技术相比,具有如下优点:设备柔性好,采用一套设备可对不同管径的管道进行焊缝修整,而且对不同尺寸管道的适应性强;焊缝修整效果好,在清除焊缝残渣的同时能够对焊缝进行热处理,明显改善了焊缝的力学性能,提高了焊缝的使用寿命;设备结构紧凑、使用安全方便,易实现整机小型化;应用范围广,适用于直径范围为219mm~325mm的不同材质金属管道。 Compared with the prior art, the present invention has the following advantages: the equipment has good flexibility, and a set of equipment can be used to repair the weld seam of pipes with different diameters, and has strong adaptability to pipes of different sizes; the effect of weld seam repair is good, Heat treatment can be performed on the weld seam while removing the weld residue, which significantly improves the mechanical properties of the weld seam and prolongs the service life of the weld seam; For metal pipes of different materials with a diameter ranging from 219mm to 325mm.

下面结合附图对本发明作进一步的说明。 The present invention will be further described below in conjunction with the accompanying drawings.

附图说明 Description of drawings

图1为本发明其中一方向的剖面结构示意图。 FIG. 1 is a schematic cross-sectional structure diagram of one direction of the present invention.

图2为本发明另一方向的剖面结构示意图。 Fig. 2 is a schematic cross-sectional structure diagram of another direction of the present invention.

图3为本发明中爬行小车的结构示意图。 Fig. 3 is a structural schematic diagram of the crawling trolley in the present invention.

图4为本发明中变径调心机构的横截面结构示意图。 Fig. 4 is a schematic diagram of the cross-sectional structure of the variable-diameter centering mechanism in the present invention.

图5为图1中CCD相机与等离子枪在I:I处的安装位置放大示意图。 Figure 5 is an enlarged schematic view of the installation position of the CCD camera and the plasma gun at I:I in Figure 1 .

图6为本发明中齿轮齿条机构与制动电磁铁的安装示意图。 Fig. 6 is a schematic diagram of the installation of the rack and pinion mechanism and the brake electromagnet in the present invention.

图7为本发明中伺服气缸的工作原理图。 Fig. 7 is a working principle diagram of the servo cylinder in the present invention.

具体实施方式 Detailed ways

如图1-图7所示,本发明所述的管道闪光对焊焊缝等离子清渣及热处理机,包括管内爬行定位机构、通过该管内爬行定位机构推动位移及定位的管内焊缝等离子清渣及热处理机构、用于控制管内爬行定位机构和管内焊缝等离子清渣及热处理机构动作的监控单元、通过监控单元控制动作的管内位置调节机构,该管内位置调节机构设置在管内爬行定位机构和管内焊缝等离子清渣及热处理机构之间。其中,如图1及图3所示,管内爬行定位机构是一种机、电、气一体化的作业小车,其包括车架1及安装在车架1上的交流电机2、行星二级减速器3、主动轮4、被动轮5、齿轮齿条机构6、制动电磁铁7和行走位移测量机构,其中行星二级减速器3的动力输入端与交流电机2的动力输出端相连接,主动轮4和齿轮齿条机构6分别与行星二级减速器3的动力输出端相连接,制动电磁铁7与齿轮齿条机构6相连接,而且小车可安装在一个小车套筒28内,在该小车套筒28上对应开设有供主动轮4、被动轮5和制动电磁铁7穿过的通孔,如图6所示,制动电磁铁7是固定安装在齿轮齿条机构6的两齿条之间,当小车到达指定位置后,行走位移测量机构发出运动位置已到达的信号后,安装在车架1下端的齿轮齿条机构6控制制动电磁铁7向下运动,制动电磁铁7下降到最低端与准备进行焊缝清渣及热处理的管道的管壁紧密接触,制动电磁铁7通电后实现对小车的固定作用,避免小车在管道内滑动,行走位移测量机构包括测长编码齿轮和旋转编码器,所述测长编码齿轮与被动轮5上设置的齿轮啮合连接,所述旋转编码器的轴端与测长编码齿轮通过键槽配合连接,被动轮5的转动等同旋转编码器的轴转动,通过旋转编码器的码盘进行计数,从而实现对爬行位置的精确控制。如图1及图2所示,管内焊缝等离子清渣及热处理机构包括用于对管内焊缝进行清渣及热处理的等离子枪23、用于调节等离子枪23使用位置的三自由度调节机构和用于监测等离子枪23清渣状态及焊缝处理效果的单目视觉监测单元。其中,三自由度调节机构包括设置在保护套筒16内的用于带动等离子枪23旋转的伺服电机17、用于带动等离子枪23径向移动的直线电机机构和用于带动等离子枪23偏转摆动的双齿轮传导机构,其中直线电机机构包括直线电机18及与直线电机18的传动轴相连接的运动导轨19,直线电机18安装在直线电机套筒20内并通过直线电机套筒20与伺服电机17的传动轴171固定连接,如图所示,直线电机套筒20与伺服电机17的传动轴171是通过轴套26相连接并通过固定联轴器15连接固定。双齿轮传导机构包括驱动电机、与驱动电机的传动轴相连接的主动齿轮21及与主动齿轮21啮合连接的被动齿轮22,所述双齿轮传导机构和等离子枪23分别安装在运动导轨19上,且所述等离子枪23与被动齿轮22固定连接并与外部的离子气及保护气设备和循环冷却水箱相连通,本发明使用时,可根据需要,通过直线电机18带动等离子枪23径向移动,实现等离子枪23的径向位移调节,并可通过双齿轮传导机构带动等离子枪23偏摆,同时通过伺服电机17经直线电机18带动等离子枪23旋转而实现等离子枪23对管内焊缝清渣及热处理需要的轴向旋转运动。单目视觉监测单元包括CCD相机24、图像采集卡、环形光源、滤波器和无线发射器,无线发射器与监控单元信号连接,CCD相机24通过支架25安装固定在三自由度调节机构上且位于等离子枪23的下方,如图1及图5所示,CCD相机24是通过支架25安装固定在直线电机套筒20上,而且CCD相机24可根据需要按圆周设置有多个,通过该单目视觉监测单元可实时并准确地检测等离子枪23的清渣工作状态及焊缝处理信息。管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的轴向位置进行微调的轴向位移微调机构,该轴向位移微调机构由伺服气缸9、电磁换向阀、压力传感器、位置传感器和控制器组成,压力传感器检测伺服气缸9两个压力室的压力信号,位置传感器检测伺服气缸9的活塞杆91的行走位移信号,经控制器计算后由伺服电机9的伺服阀精确控制活塞杆91的行走位移,从而实现等离子枪23的轴向微调功能,如图7所示,为伺服气缸9的工作原理图,当管内焊缝等离子清渣及热处理机构未调整到预定位置时,电磁换向阀切向右端,整个气动回路接通,气体推动伺服气缸9的活塞杆91向前运动,推动管内焊缝等离子清渣及热处理机构向前运动;当管内焊缝等离子清渣及热处理机构超过预定位置时,电磁换向阀切向左端,整个气动回路方向接通,气体推动伺服气缸9的活塞杆91向后运动,带动管内焊缝等离子清渣及热处理机构向后运动;当管内焊缝等离子清渣及热处理机构恰好调整到预定位置时,控制电磁换向阀处于截止位置,伺服气缸9维持不动状态,实现精确定位功能。进一步地,管内位置调节机构还包括用于对管内焊缝等离子清渣及热处理机构的径向位置进行粗调的丝杆调节机构8,该丝杆调节机构8由调节丝杆和调节螺母组成且连接在管内爬行定位机构上,如图2及图3所示,伺服气缸9安装在气缸支架27上并通过丝杆调节机构8连接在车架1的上部,通过丝杆调节机构8上的调节螺母可使车架1上方的伺服气缸9升高或降低实现变径,从而满足不同直径管道的需求,最大变径调节范围为106mm。更进一步地,管内位置调节机构还包括用于对管内焊缝等离子清渣及热处理机构的径向位置进行精调的变径调心机构,如图1、图2及图4所示,该变径调心机构包括连接轴11及连接轴11两端各设置的一组气动调心定位机构12,各组气动调心定位机构12分别由连接套121、固定在连接套121上且按圆周均匀排布的三个气缸122及各气缸122的活塞杆外端连接的一个球形压轮123组成,其中连接轴11的一端通过两个万向联轴器10与伺服气缸9的活塞杆91同轴连接,其一端通过固定联轴器15与伺服电机17同轴连接,而且在连接轴11内设置有与各气缸122的气路相连通的气管。并且,变径调心机构可安装在一个调心机构套筒29内,同时在该调心机构套筒29对应各球形压轮123的位置处分别开设有一个可供各球形压轮123穿行的通孔。监控单元包括机载控制单元和管外监控单元,其中机载控制单元包括PLC控制器14及与PLC控制器14电连接的无线数据传输器13,PLC控制器14和无线数据传输器13通过固定联轴器15连接在连接轴11上并位于两组气动调心定位机构12之间,交流电机2、伺服气缸9、气缸122、伺服电机17和等离子枪23分别与PLC控制器14电连接,且PLC控制器14连接有电源,管外监控单元包括图像监视器、无线收发信号单元、离子气及保护气控制单元、循环冷却水箱控制单元、焊缝图像算法处理单元、管内爬行定位机构位移控制单元和等离子枪位姿调节控制单元,无线数据传输器13与收发信号单元信号连接,通过管外监控单元能够方便地实现管道内部焊缝的等离子清渣及热处理功能。 As shown in Figures 1 to 7, the plasma slag removal and heat treatment machine for pipeline flash butt welding according to the present invention includes a crawling positioning mechanism in the pipe, and a plasma slag cleaning of the weld seam in the pipe that is displaced and positioned by the crawling positioning mechanism in the pipe And the heat treatment mechanism, the monitoring unit used to control the action of the crawling positioning mechanism in the tube and the plasma slag removal and heat treatment mechanism in the tube, the position adjustment mechanism in the tube controlled by the monitoring unit, the position adjustment mechanism in the tube is set in the crawling positioning mechanism in the tube and the inside of the tube Between weld plasma slag cleaning and heat treatment mechanism. Among them, as shown in Figure 1 and Figure 3, the crawling positioning mechanism in the pipe is a mechanical, electrical and pneumatic integrated operation trolley, which includes a vehicle frame 1 and an AC motor 2 installed on the vehicle frame 1, and a planetary two-stage reduction gear. device 3, driving wheel 4, driven wheel 5, rack and pinion mechanism 6, brake electromagnet 7 and travel displacement measuring mechanism, wherein the power input end of planetary secondary reducer 3 is connected with the power output end of AC motor 2, The driving wheel 4 and the rack and pinion mechanism 6 are respectively connected to the power output end of the planetary secondary reducer 3, the brake electromagnet 7 is connected to the rack and pinion mechanism 6, and the trolley can be installed in a trolley sleeve 28, The trolley sleeve 28 is correspondingly provided with through holes for the driving wheel 4, the driven wheel 5 and the braking electromagnet 7 to pass through. As shown in Figure 6, the braking electromagnet 7 is fixedly mounted on the rack and pinion mechanism 6 Between the two racks of the trolley, when the trolley reaches the designated position, the travel displacement measuring mechanism sends out a signal that the movement position has been reached, and the rack and pinion mechanism 6 installed at the lower end of the frame 1 controls the braking electromagnet 7 to move downward to stop The moving electromagnet 7 descends to the lowest end and is in close contact with the pipe wall of the pipeline for welding slag cleaning and heat treatment. After the brake electromagnet 7 is energized, it can fix the trolley to prevent the trolley from sliding in the pipeline, and the travel displacement measurement mechanism It includes a length-measuring coding gear and a rotary encoder. The length-measuring coding gear is meshed with the gear provided on the driven wheel 5. The shaft end of the rotary encoder is connected with the length-measuring coding gear through a keyway. The rotation of the driven wheel 5 Equivalent to the rotation of the shaft of the rotary encoder, counting is performed by the code disc of the rotary encoder, so as to realize the precise control of the crawling position. As shown in Figure 1 and Figure 2, the plasma slag removal and heat treatment mechanism for the weld in the pipe includes a plasma gun 23 for slag removal and heat treatment for the weld in the pipe, a three-degree-of-freedom adjustment mechanism for adjusting the use position of the plasma gun 23 and A monocular vision monitoring unit for monitoring the slag removal status of the plasma gun 23 and the treatment effect of the weld seam. Among them, the three-degree-of-freedom adjustment mechanism includes a servo motor 17 for driving the plasma gun 23 to rotate, a linear motor mechanism for driving the plasma gun 23 to move radially, and a linear motor mechanism for driving the plasma gun 23 to deflect and swing. The double-gear transmission mechanism, wherein the linear motor mechanism includes a linear motor 18 and a motion guide rail 19 connected to the transmission shaft of the linear motor 18, the linear motor 18 is installed in the linear motor sleeve 20 and is connected to the servo motor through the linear motor sleeve 20 The transmission shaft 171 of 17 is fixedly connected, as shown in the figure, the linear motor sleeve 20 and the transmission shaft 171 of the servo motor 17 are connected through the shaft sleeve 26 and connected and fixed through the fixed coupling 15 . The double-gear transmission mechanism comprises a drive motor, a driving gear 21 connected to the transmission shaft of the drive motor, and a driven gear 22 meshed with the drive gear 21, and the double-gear transmission mechanism and the plasma gun 23 are installed on the motion guide rail 19 respectively. And the plasma gun 23 is fixedly connected with the driven gear 22 and communicated with the external ion gas and protective gas equipment and the circulating cooling water tank. When the present invention is used, the linear motor 18 can drive the plasma gun 23 to move radially according to the needs. The radial displacement adjustment of the plasma gun 23 can be realized, and the plasma gun 23 can be driven to yaw through the double gear transmission mechanism. Axial rotational motion required for heat treatment. The monocular vision monitoring unit includes a CCD camera 24, an image acquisition card, a ring light source, a filter and a wireless transmitter, the wireless transmitter is connected to the monitoring unit signal, and the CCD camera 24 is installed and fixed on the three-degree-of-freedom adjustment mechanism through a bracket 25 and is located at Below the plasma gun 23, as shown in Figure 1 and Figure 5, the CCD camera 24 is installed and fixed on the linear motor sleeve 20 by a support 25, and the CCD camera 24 can be provided with a plurality of by the circumference as required, through the monocular The visual monitoring unit can detect the slag removal working status and welding seam processing information of the plasma gun 23 in real time and accurately. The position adjustment mechanism in the pipe includes an axial displacement fine-tuning mechanism for fine-tuning the axial position of the plasma slag cleaning and heat treatment mechanism in the pipe. The axial displacement fine-tuning mechanism consists of a servo cylinder 9, an electromagnetic reversing valve, a pressure sensor, a position Composed of sensors and controllers, the pressure sensor detects the pressure signals of the two pressure chambers of the servo cylinder 9, the position sensor detects the walking displacement signal of the piston rod 91 of the servo cylinder 9, and the servo valve of the servo motor 9 precisely controls the piston after calculation by the controller The walking displacement of the rod 91 realizes the axial fine-tuning function of the plasma gun 23. As shown in Figure 7, it is the working principle diagram of the servo cylinder 9. The reversing valve is switched to the right end, the entire pneumatic circuit is connected, the gas pushes the piston rod 91 of the servo cylinder 9 to move forward, and the plasma slag cleaning and heat treatment mechanism in the pipe moves forward; when the plasma slag cleaning and heat treatment mechanism in the pipe When the predetermined position is exceeded, the electromagnetic reversing valve is switched to the left end, the direction of the entire pneumatic circuit is connected, and the gas pushes the piston rod 91 of the servo cylinder 9 to move backward, driving the plasma slag removal and heat treatment mechanism of the weld seam in the pipe to move backward; When the seam plasma slag cleaning and heat treatment mechanism is just adjusted to the predetermined position, the control electromagnetic reversing valve is in the cut-off position, and the servo cylinder 9 remains in a stationary state to realize the precise positioning function. Further, the position adjustment mechanism in the pipe also includes a screw adjustment mechanism 8 for rough adjustment of the radial position of the welding seam plasma slag removal and heat treatment mechanism in the pipe. The screw adjustment mechanism 8 is composed of an adjustment screw and an adjustment nut. Connected to the crawling positioning mechanism in the pipe, as shown in Figure 2 and Figure 3, the servo cylinder 9 is installed on the cylinder bracket 27 and connected to the upper part of the vehicle frame 1 through the screw adjustment mechanism 8, and adjusted by the screw adjustment mechanism 8 The nut can raise or lower the servo cylinder 9 on the top of the vehicle frame 1 to achieve diameter reduction, thereby meeting the needs of pipes with different diameters, and the maximum diameter reduction adjustment range is 106mm. Furthermore, the position adjustment mechanism in the pipe also includes a diameter-changing centering mechanism for fine adjustment of the radial position of the welding seam plasma slag removal and heat treatment mechanism in the pipe, as shown in Figure 1, Figure 2 and Figure 4. The diameter centering mechanism includes the connecting shaft 11 and a group of pneumatic centering positioning mechanisms 12 respectively provided at both ends of the connecting shaft 11. Three arranged cylinders 122 and a spherical pressure wheel 123 connected to the outer ends of the piston rods of each cylinder 122 are composed, wherein one end of the connecting shaft 11 is coaxial with the piston rod 91 of the servo cylinder 9 through two universal couplings 10 Connect, one end of which is coaxially connected with the servo motor 17 through a fixed coupling 15, and an air pipe communicating with the air passage of each cylinder 122 is provided in the connecting shaft 11. And, the variable-diameter centering mechanism can be installed in a centering mechanism sleeve 29, and at the same time at the position of the corresponding spherical pressure rollers 123 of the centering mechanism sleeve 29, there is respectively provided a space for each spherical pressure roller 123 to pass through. through hole. The monitoring unit includes an airborne control unit and an external monitoring unit, wherein the airborne control unit includes a PLC controller 14 and a wireless data transmitter 13 electrically connected to the PLC controller 14, and the PLC controller 14 and the wireless data transmitter 13 pass through a fixed The shaft coupling 15 is connected to the connecting shaft 11 and is located between two groups of pneumatic centering positioning mechanisms 12. The AC motor 2, the servo cylinder 9, the cylinder 122, the servo motor 17 and the plasma gun 23 are respectively electrically connected to the PLC controller 14, In addition, the PLC controller 14 is connected to a power supply, and the monitoring unit outside the tube includes an image monitor, a wireless transceiver unit, an ion gas and shielding gas control unit, a circulating cooling water tank control unit, a weld image algorithm processing unit, and a displacement control unit for crawling positioning mechanisms in the tube. The unit and the plasma gun position adjustment control unit, the wireless data transmitter 13 are connected with the signal receiving unit, and the plasma slag cleaning and heat treatment functions of the internal weld seam of the pipeline can be easily realized through the monitoring unit outside the pipe.

本发明的工作原理是:管外监测单元接收CCD相机24采集到的焊缝图像信息,通过PLC控制器14发出控制指令,驱动管内爬行定位机构、轴向位移微调机构、变径调心机构、三自由度调节机构和等离子枪23运动,实现爬行、定位、清渣及热处理,清渣过程实时监测等功能。整个过程也可分为三个阶段,第一阶段:管内爬行定位机构把管内焊缝等离子清渣及热处理机构送到准备进行焊缝清渣及热处理的管道的焊缝处,焊缝位置处的定位通过CCD相机24来确定。当管内焊缝等离子清渣及热处理机构到达指定位置后,控制制动电磁铁7使之吸住管道的管壁以固定管内爬行定位机构,然后用车架1上的伺服气缸9轴向微调管内焊缝等离子清渣及热处理机构的位置实现精确定位;第二阶段:控制变径调心机构的六个气缸122让管道轴线与管内焊缝等离子清渣及热处理机构的轴线重合,实现调心功能,当管道轴线与管内焊缝等离子清渣及热处理机构的轴线重合后,通过各气缸122的活塞杆外端的球形压轮123紧压管道的内壁,实现定位功能;第三阶段:通过三自由度调节机构的直线电机机构和双齿轮传动机构让等离子枪23的枪嘴与管内焊缝残渣保持工艺要求姿态,然后通过伺服电机17旋转带动等离子枪23轴向旋转,实现管道的管内焊缝等离子清渣及热处理。 The working principle of the present invention is: the monitoring unit outside the tube receives the image information of the weld seam collected by the CCD camera 24, sends a control command through the PLC controller 14, drives the crawling positioning mechanism in the tube, the axial displacement fine-tuning mechanism, the variable diameter centering mechanism, The three-degree-of-freedom adjustment mechanism and the movement of the plasma gun 23 realize functions such as crawling, positioning, slag removal and heat treatment, and real-time monitoring of the slag removal process. The whole process can also be divided into three stages. The first stage: the crawling positioning mechanism in the pipe sends the plasma slag cleaning and heat treatment mechanism of the weld seam in the pipe to the weld seam of the pipeline for welding seam slag removal and heat treatment, and the welding seam position Positioning is determined by a CCD camera 24 . When the plasma slag cleaning and heat treatment mechanism of the weld seam in the pipe reaches the designated position, control the brake electromagnet 7 to make it suck the pipe wall to fix the crawling positioning mechanism in the pipe, and then use the servo cylinder 9 on the frame 1 to fine-tune the inner pipe The position of the weld plasma slag removal and heat treatment mechanism realizes precise positioning; the second stage: control the six cylinders 122 of the variable diameter centering mechanism to make the pipeline axis coincide with the axis of the weld plasma slag removal and heat treatment mechanism in the pipe to realize the centering function , when the axis of the pipeline coincides with the axis of the plasma slag cleaning and heat treatment mechanism in the pipe, the spherical pressure roller 123 at the outer end of the piston rod of each cylinder 122 is pressed against the inner wall of the pipeline to realize the positioning function; the third stage: through three degrees of freedom The linear motor mechanism and the double gear transmission mechanism of the adjustment mechanism keep the nozzle of the plasma gun 23 and the welding seam residue in the pipe to maintain the attitude required by the process, and then the rotation of the servo motor 17 drives the plasma gun 23 to rotate axially, so as to realize the plasma cleaning of the weld seam in the pipe. slag and heat treatment.

本发明是通过实施例来描述的,但并不对本发明构成限制,参照本发明的描述,所公开的实施例的其他变化,如对于本领域的专业人士是容易想到的,这样的变化应该属于本发明权利要求限定的范围之内。 The present invention is described by the embodiment, but does not constitute limitation to the present invention, with reference to the description of the present invention, other changes of the disclosed embodiment, if it is easy to imagine for those skilled in the art, such changes should belong to Within the scope defined by the claims of the present invention.

Claims (10)

1.一种管道闪光对焊管内焊缝等离子清渣及热处理机,其特征在于包括管内爬行定位机构、通过该管内爬行定位机构推动位移及定位的管内焊缝等离子清渣及热处理机构、用于控制管内爬行定位机构和管内焊缝等离子清渣及热处理机构动作的监控单元。 1. A plasma slag removal and heat treatment machine for weld seams in pipeline flash butt welded pipes, characterized in that it includes a crawling positioning mechanism in the pipe, a plasma slag removal and heat treatment mechanism for the welding seam in the pipe that is pushed and displaced and positioned by the crawling positioning mechanism in the pipe, and is used for A monitoring unit that controls the movement of the crawling positioning mechanism in the pipe and the plasma slag cleaning and heat treatment mechanism for the weld seam in the pipe. 2.根据权利要求1所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于还包括有通过监控单元控制动作的管内位置调节机构,所述管内位置调节机构设置在管内爬行定位机构和管内焊缝等离子清渣及热处理机构之间。 2. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 1, characterized in that it also includes an in-pipe position adjustment mechanism controlled by a monitoring unit, and the in-pipe position adjustment mechanism is arranged on a crawling positioning mechanism in the pipe Between the plasma slag cleaning and heat treatment mechanism of the weld seam in the pipe. 3.根据权利要求2所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的径向位置进行粗调的丝杆调节机构(8),该丝杆调节机构(8)由调节丝杆和调节螺母组成且连接在管内爬行定位机构上。 3. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 2, characterized in that the position adjustment mechanism in the pipe includes a device for roughly adjusting the radial position of the plasma slag removal and heat treatment mechanism for the weld seam in the pipe A screw adjustment mechanism (8), the screw adjustment mechanism (8) is composed of an adjustment screw and an adjustment nut and is connected to the crawling positioning mechanism in the tube. 4.根据权利要求2所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的径向位置进行精调的变径调心机构,该变径调心机构包括连接轴(11)及连接轴(11)两端各设置的一组气动调心定位机构(12),所述各组气动调心定位机构(12)分别由连接套(121)、固定在连接套(121)上且按圆周均匀排布的三个气缸(122)及各气缸(122)的活塞杆外端连接的一个球形压轮(123)组成。 4. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 2, characterized in that the position adjustment mechanism in the pipe includes a device for fine adjustment of the radial position of the plasma slag removal and heat treatment mechanism for the weld seam in the pipe A variable diameter centering mechanism, the variable diameter centering mechanism includes a connecting shaft (11) and a set of pneumatic centering positioning mechanisms (12) provided at both ends of the connecting shaft (11), each set of pneumatic centering positioning mechanisms ( 12) A spherical pressure wheel (123) connected by the connection sleeve (121), three cylinders (122) fixed on the connection sleeve (121) and arranged uniformly on the circumference, and the outer ends of the piston rods of each cylinder (122) )composition. 5.根据权利要求2所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述管内位置调节机构包括用于对管内焊缝等离子清渣及热处理机构的轴向位置进行微调的轴向位移微调机构,该轴向位移微调机构由伺服气缸(9)、电磁换向阀、压力传感器、位置传感器和控制器组成。 5. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 2, characterized in that the position adjustment mechanism in the pipe includes a shaft for fine-tuning the axial position of the plasma slag removal and heat treatment mechanism for the weld seam in the pipe An axial displacement fine-tuning mechanism is composed of a servo cylinder (9), an electromagnetic reversing valve, a pressure sensor, a position sensor and a controller. 6.根据权利要求1所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述管内焊缝等离子清渣及热处理机构包括用于对管内焊缝进行清渣及热处理的等离子枪(23)、用于调节等离子枪(23)使用位置的三自由度调节机构和用于监测等离子枪(23)清渣状态及焊缝处理效果的单目视觉监测单元。 6. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 1, characterized in that the plasma slag removal and heat treatment mechanism for the weld seam in the pipe includes a plasma gun ( 23). A three-degree-of-freedom adjustment mechanism for adjusting the use position of the plasma gun (23) and a monocular visual monitoring unit for monitoring the slag removal status of the plasma gun (23) and the effect of welding seam treatment. 7.根据权利要求6所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述三自由度调节机构包括用于带动等离子枪(23)旋转的伺服电机(17)、用于带动等离子枪(23)径向移动的直线电机机构和用于带动等离子枪(23)偏转摆动的双齿轮传导机构,其中所述直线电机机构包括直线电机(18)及与直线电机(18)的传动轴相连接的运动导轨(19),所述直线电机(18)安装在直线电机套筒(20)内并通过直线电机套筒(20)与伺服电机(17)的传动轴(171)固定连接,所述双齿轮传导机构包括驱动电机、与驱动电机的传动轴相连接的主动齿轮(21)及与主动齿轮(21)啮合连接的被动齿轮(22),所述双齿轮传导机构和等离子枪(23)分别安装在运动导轨(19)上,且所述等离子枪(23)与被动齿轮(22)固定连接并与外部的离子气及保护气设备和循环冷却水箱相连通。 7. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 6, characterized in that the above-mentioned three-degree-of-freedom adjustment mechanism includes a servo motor (17) for driving the plasma gun (23) to rotate, and a servo motor (17) for driving The linear motor mechanism for the radial movement of the plasma gun (23) and the double-gear transmission mechanism for driving the plasma gun (23) to deflect and swing, wherein the linear motor mechanism includes a linear motor (18) and a transmission with the linear motor (18) A motion guide rail (19) connected to the shaft, the linear motor (18) is installed in the linear motor sleeve (20) and fixedly connected with the transmission shaft (171) of the servo motor (17) through the linear motor sleeve (20) , the double-gear transmission mechanism includes a driving motor, a driving gear (21) connected to the transmission shaft of the driving motor, and a driven gear (22) meshed with the driving gear (21), the double-gear transmission mechanism and the plasma gun (23) are respectively installed on the moving guide rails (19), and the plasma gun (23) is fixedly connected with the driven gear (22) and communicated with the external ion gas and protective gas equipment and the circulating cooling water tank. 8.根据权利要求6所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述单目视觉监测单元包括CCD相机(24)、图像采集卡、环形光源、滤波器和无线发射器,所述无线发射器与监控单元信号连接,所述CCD相机(24)通过支架(25)安装固定在三自由度调节机构上且位于等离子枪(23)的下方。 8. The plasma slag removal and heat treatment machine for pipeline flash butt welding according to claim 6, characterized in that the monocular vision monitoring unit includes a CCD camera (24), an image acquisition card, a ring light source, a filter and a wireless transmitter , the wireless transmitter is signal-connected with the monitoring unit, and the CCD camera (24) is installed and fixed on the three-degree-of-freedom adjustment mechanism through a bracket (25) and is located below the plasma gun (23). 9.根据权利要求1所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述管内爬行定位机构包括车架(1)及安装在车架(1)上的交流电机(2)、行星二级减速器(3)、主动轮(4)、被动轮(5)、齿轮齿条机构(6)、制动电磁铁(7)和行走位移测量机构,其中所述行星二级减速器(3)的动力输入端与交流电机(2)的动力输出端相连接,所述主动轮(4)和齿轮齿条机构(6)分别与行星二级减速器(3)的动力输出端相连接,所述制动电磁铁(7)与齿轮齿条机构(6)相连接,所述行走位移测量机构包括测长编码齿轮和旋转编码器,所述测长编码齿轮与被动轮(5)上设置的齿轮啮合连接,所述旋转编码器的轴端与测长编码齿轮通过键槽配合连接。 9. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 1, characterized in that the crawling positioning mechanism in the pipe includes a vehicle frame (1) and an AC motor (2) installed on the vehicle frame (1) , planetary secondary reducer (3), driving wheel (4), driven wheel (5), rack and pinion mechanism (6), brake electromagnet (7) and travel displacement measuring mechanism, wherein the planetary secondary reducer The power input end of the device (3) is connected to the power output end of the AC motor (2), and the driving wheel (4) and the rack and pinion mechanism (6) are respectively connected to the power output end of the planetary two-stage reducer (3). connected, the brake electromagnet (7) is connected with the rack and pinion mechanism (6), the travel displacement measuring mechanism includes a length measuring coded gear and a rotary encoder, and the length measuring coded gear is connected with the driven wheel (5 ) is meshed with the gears provided on it, and the shaft end of the rotary encoder is connected with the length-measuring coding gear through a keyway. 10.根据权利要求1所述管道闪光对焊焊缝等离子清渣及热处理机,其特征在于上述监控单元包括机载控制单元和管外监控单元,所述机载控制单元包括PLC控制器(14)及与PLC控制器(14)电连接的无线数据传输器(13),所述管外监控单元包括图像监视器、无线收发信号单元、离子气及保护气控制单元、循环冷却水箱控制单元、焊缝图像算法处理单元、管内爬行定位机构位移控制单元和等离子枪位姿调节控制单元,所述无线数据传输器(13)与收发信号单元信号连接。 10. The plasma slag removal and heat treatment machine for pipeline flash butt welding seam according to claim 1, characterized in that the above-mentioned monitoring unit includes an on-board control unit and an external monitoring unit, and the on-board control unit includes a PLC controller (14 ) and a wireless data transmitter (13) electrically connected to the PLC controller (14), the external monitoring unit includes an image monitor, a wireless transceiver unit, an ion gas and protective gas control unit, a circulating cooling water tank control unit, The welding seam image algorithm processing unit, the displacement control unit of the crawling positioning mechanism in the pipe, and the plasma gun pose adjustment control unit, and the wireless data transmitter (13) is connected to the signal sending and receiving unit.
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CN113878296B (en) * 2021-10-28 2023-08-25 Dig自动化工程(武汉)有限公司 Internal support device for welding long pipeline

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