CN-122007549-A - Automatic surfacing equipment and method for inner wall of multi-machine-head cylinder

CN122007549ACN 122007549 ACN122007549 ACN 122007549ACN-122007549-A

Abstract

The invention discloses a multi-head barrel inner wall automatic surfacing equipment and a method, which are capable of realizing the non-splashing transition of molten drops and the high stability of electric arcs under the condition of low heat input by integrating ASMT cooperative control technology into an automatic welding system, are particularly suitable for welding working conditions of quick heat dissipation and limited operation space of the barrel inner wall, and realize the deep fusion of ASMT technology and automatic equipment. By means of the ASMT/CMT technology, the precise regulation and control of the heat input amount and the dilution rate and the dynamic path correction of laser tracking are matched, so that the chemical components, the mechanical property, the corrosion resistance and the geometric morphology of the surfacing layer are ensured to show extremely high uniformity and stability, the performance index is superior to that of the traditional manual welding, continuous and high-speed surfacing operation is achieved by automatic special equipment, the deposition efficiency is remarkably improved, the dependence on high-skill welders is reduced while the manufacturing period is shortened, and the whole production cost is reduced.

Inventors

MA XIAOBING
CHEN HAO
WANG SHIYONG
AN TIANYOU
YAO XINGYU
LUO YONGZHI
LI FUFU
Xi Yaobang
QIN WENHAI
WANG YAN

Assignees

新疆兰石重装能源工程有限公司

Dates

Publication Date: 20260512
Application Date: 20260407

Claims (7)

1. The automatic build-up welding equipment for the inner wall of the multi-head cylinder body is characterized by comprising a stand column, a cross arm, a roller frame, a wheel blocking type channeling prevention mechanism, a laser welding seam tracking device and a molten pool monitoring device, wherein a plurality of build-up welding heads are arranged on the cross arm, the cross arm is connected with the stand column through a lifting translation mechanism, the cross arm can move along the height direction of the stand column and the direction perpendicular to the stand column, the build-up welding heads are connected with the cross arm through a moving mechanism, and the build-up welding heads can move along the length direction of the cross arm.
2. The automatic build-up welding device for the inner wall of the barrel with multiple machine heads according to claim 1, wherein the lifting and translation mechanism comprises a lifting support, a lifting driving mechanism and a translation driving mechanism, tracks are arranged on two sides of the upright post, two groups of track wheels are arranged on two sides of the lifting support, the track wheels are connected with the tracks in a matched mode, sliding rails are arranged on the top and the bottom of the cross arm, a first sliding seat matched with the sliding rails is arranged on the lifting support, the sliding rails are connected with the first sliding seat in a matched sliding mode, the lifting driving mechanism is used for driving the lifting support to ascend and descend along the upright post, and the translation driving mechanism is used for driving the cross arm to move in the horizontal direction.
3. The automatic overlaying device for the inner wall of the multi-head cylinder according to claim 2, wherein the moving mechanism comprises a head driving mechanism and a second sliding seat arranged on a frame of the overlaying head, the second sliding seat is in matched sliding connection with the sliding rail, and the head driving mechanism is used for driving the overlaying head to move along the length direction of the cross arm.
4. A build-up welding method based on the automatic build-up welding equipment for the inner wall of a multi-machine-head cylinder body is characterized in that, S1, carrying out grinding and cleaning operation on the inner surface of a workpiece to be surfacing until the metal luster appears, carrying out 100% magnetic powder detection, mounting the workpiece on a roller frame after confirming no defect, enabling a cross arm to extend into the workpiece, S2, presetting a surfacing process parameter combination, wherein the surfacing process parameter combination covers the controlled range of welding current, voltage, running speed, swing amplitude parameter and heat input quantity, the welding current is set to 190-220A, the voltage fluctuation range is 23.7-24.3V, the welding advancing speed is 4.5-4.7 m/min, the wire feeding speed is maintained at 9-10 m/min, the swing amplitude is controlled at 5-8mm, the swing frequency corresponding speed is 2000 mm/min, the stay time at the left end, the right end and the central position is set to 0.1-0.3S, the parameters are combined into a plurality of formula packages in advance according to the combination of surfacing pose, base metal and filling metal, the formula packages are directly called during surfacing, S3, controlling the total thickness of the surfacing layer to be in a range of 4.0-4.5mm, completing the multilayer multi-channel automatic surfacing process by a two-layer process, before surfacing, moving a plurality of surfacing heads to the initial position to be welded of the inner wall of the cylinder, scanning and identifying the initial point of a welding seam by utilizing a laser welding seam tracking device, observing the relative position of a welding gun and a workpiece by utilizing a molten pool monitoring device, precisely fine-tuning to enable the welding gun to be aligned to the initial position, driving the cylinder to rotate at a constant speed by a roller frame after the welding starts, moving the welding gun along the axis direction of the cylinder at a set speed (corresponding to a spiral surfacing mode) or keeping a fixed position (corresponding to a circumferential seam surfacing mode), and swinging the welding gun according to preset parameters; A first layer (transition layer) for performing build-up welding under the condition that the preheating temperature of the workpiece is not lower than 80 ℃, strictly limiting the inter-channel temperature to 80-250 ℃, setting the width of the channel weld to 20-25mm, and taking the overlapping proportion between adjacent weld beads to 1/3-1/2 of the welding width; After the first layer of welding task is finished, naturally cooling the surface of the surfacing to below 250 ℃ if necessary, cleaning slag and splashing impurities, and executing 100% penetration flaw detection (PT) on the surface of the layer; And a second layer (surface layer) which is formed by performing surface layer surfacing in a more severe low temperature range (15-100 ℃) after the transition layer is cooled to room temperature, and performing 100% PT detection and 100% ultrasonic flaw detection on the surface of the surface layer after the surfacing procedure is ended.
5. The method of claim 1, wherein the laser tracking system detects the weld position deviation in real time during overlay welding and dynamically adjusts the lateral position of the welding gun.
6. The method of claim 1, wherein after the build-up operation is completed, a stress relief heat treatment is performed, and after the heat treatment is completed, a final quality check is performed on the build-up layer: the geometric dimension and apparent quality inspection, namely, the surface of a surfacing layer is required to be smooth and symmetrical, the depth of trough between adjacent welding beads and the unevenness of joint positions are required to be controlled within 0.8mm, and multi-site measurement is carried out through an ultrasonic thickness measuring device, so as to verify that the thickness of the surfacing layer is not lower than a designed specified value; Nondestructive testing (NDT) by re-performing 100% Ultrasonic Testing (UT); chemical component analysis, namely sampling from the surface layer of the build-up layer, a position 1.5mm below the surface layer and a half site of the thickness of the build-up layer (ensuring the distance between the build-up layer and the base layer is not more than 2 mm), measuring chemical components by utilizing a spectrum analyzer, and mainly monitoring the concentration of iron (Fe) elements (the depth of which is required to be less than or equal to 5 percent at the depth of 1.5 mm); And (3) measuring hardness performance, namely respectively measuring the Vickers hardness (HV 10) of the surface of the build-up layer, the surface layer area, the transition layer, the heat affected zone and the parent metal, wherein the hardness value of the surface of the build-up layer is required to be stabilized in the range of 210-230 HV.
7. The method of claim 1, wherein the form and stability of the weld puddle are observed in real time by a puddle monitoring device during overlay welding, the system synchronously records the video of the whole welding process, and stores corresponding process parameters, thereby finally forming a traceable welding process data packet.

Description

Automatic surfacing equipment and method for inner wall of multi-machine-head cylinder Technical Field The invention belongs to the field of special equipment manufacturing and welding clamps, and particularly relates to automatic build-up welding equipment and method for inner walls of multi-machine-head cylinders. Background In the fields of petrochemical industry, pressure vessels, pipelines and other manufacturing fields, the inner wall of a cylinder body is usually subjected to surfacing treatment so as to enhance the corrosion resistance and the wear resistance of the cylinder body. For a long time, the inner wall surfacing is mainly dependent on a manual or semi-automatic welding mode, and the problems of poor welding quality stability, high labor intensity of operators, poor working environment, low production efficiency and the like are generally faced. Although partially automated welding equipment has been developed, the following drawbacks remain in practical engineering applications: 1. workpiece clamping and axial float control are difficult: The cylinder body is easy to generate axial movement in the rotary welding process, so that welding bead deflection or uneven interlayer lap joint is caused, and the forming quality of the overlaying layer is finally affected; 2. the welding process is poorly visible: because the welding space of the inner wall is narrow, an operator is difficult to directly observe the state of the molten pool and can only adjust the state by experience, so that the control precision of the welding parameters is insufficient; 3. The welding process has low adaptability: aiming at the cylinder bodies with different materials, diameters and lengths, the conventional equipment often lacks flexible parameter adjustment and storage capacity, and is difficult to adapt to the welding requirements of various workpieces; 4. the level of automation is limited: most of the equipment still needs manual intervention in links such as welding gun centering, welding seam tracking and the like, and the whole process from positioning to welding can not be automatically closed-loop controlled; 5. the traceability of welding quality is not enough: the lack of effective real-time monitoring and data recording means in the welding process is unfavorable for the optimization of the subsequent process and the quality tracing. In summary, research and development of a special device and a process method thereof capable of realizing high-quality, high-efficiency and full-automatic build-up welding of the inner wall of the cylinder have important engineering application values. Disclosure of Invention (1) The technical problem to be solved is to provide an automatic surfacing equipment and method for the inner wall of a multi-machine-head cylinder body, which aims to realize uniform and attractive welding bead forming, accurate and controllable penetration and width, stable and reliable welding process, is applicable to workpieces with various specifications, and constructs an automatic surfacing system with the whole process monitoring and data management functions. (2) The technical scheme adopted by the invention is as follows: The utility model provides an automatic build-up welding equipment of multi-head barrel inner wall, includes stand, xarm, gyro wheel frame, keeps off wheel formula and prevents scurrying mechanism, laser welding seam tracking means and molten pool monitoring device, sets up a plurality of build-up welding heads on the xarm, the xarm passes through lift translation mechanism with the stand and is connected, and the xarm can be followed stand direction of height and direction activity of perpendicular to stand, build-up welding head passes through moving mechanism with the xarm and is connected, and build-up welding head can be followed xarm length direction activity. Further technical scheme lies in, lift translation mechanism includes lift support, lift actuating mechanism and translation actuating mechanism, and the stand both sides set up the track, and lift support both sides all are provided with two sets of rail wheels, and rail wheels and track cooperation are connected, the top and the bottom of xarm all are provided with the slide rail, be provided with the first slide that matches with the slide rail on the lift support, slide rail and first slide cooperation sliding connection, lift actuating mechanism are used for driving lift support along the stand rise and descend, and translation actuating mechanism is used for driving the xarm and removes along the horizontal direction. The further technical scheme is that the moving mechanism comprises a machine head driving mechanism and a second sliding seat arranged on the frame of the overlaying machine head, the second sliding seat is in matched sliding connection with the sliding rail, and the machine head driving mechanism is used for driving the overlaying machine head to move along the length direction of the cr