CN-122007698-A - Water wall pipe high-precision welding processing technology based on real-time temperature control monitoring

CN122007698ACN 122007698 ACN122007698 ACN 122007698ACN-122007698-A

Abstract

The invention relates to the technical field of welding, in particular to a high-precision welding processing technology of a water wall pipe based on real-time temperature control monitoring, which is characterized in that the cross section of the water wall pipe is divided into a plurality of welding areas, corresponding detection images are acquired, wall pipe characterization parameters are calculated based on the thickness of the wall pipe and the bevel angle of the wall pipe, the pre-welded water wall pipe is heated, welding seam infrared images are acquired, water film characteristic parameters are calculated based on the temperature of the wall pipe acquired by the welding seam infrared images to judge whether the water wall pipe meets the water film forming requirement or not, the reason that the water wall pipe does not meet the water film forming requirement is judged based on the water film deviation parameters, the pretreatment parameters are adjusted based on the water film deviation parameters or the intercepting length is adjusted, the water film deviation threshold is adjusted based on the dyeing deviation parameters, and the temperature rise rate of the water wall pipe is acquired to judge whether the water film thickness is qualified or not. The invention improves the accuracy of the high-precision welding processing technology of the water wall pipe based on real-time temperature control monitoring.

Inventors

QI JUN
ZHU YU

Assignees

张家港华益特种设备有限公司

Dates

Publication Date: 20260512
Application Date: 20260413

Claims (10)

1. A water wall pipe high-precision welding processing technology based on real-time temperature control monitoring is characterized by comprising the following steps: Dividing the cross section of the water wall pipe into a plurality of welding areas, collecting corresponding detection images, respectively calculating the thickness and the bevel angle of the wall pipe in each welding area, and calculating the characterization parameters of the wall pipe based on the thickness and the bevel angle of the wall pipe; Determining the risk trend and pretreatment parameters of the water wall pipe and the intercepting length of the water wall pipe subjected to the pre-welding risk according to the comparison result of the wall pipe characterization parameters and the wall pipe standard parameters; Heating the pre-welded water wall pipe, collecting a weld infrared image, acquiring a wall pipe temperature based on the weld infrared image, calculating water film characteristic parameters of a single welding flow section based on the wall pipe temperature, judging whether the water wall pipe meets the water film forming requirement or not, responding to the water wall pipe not meeting the water film forming requirement, and judging the reason that the water wall pipe does not meet the water film forming requirement based on the water film deviation parameter; Introducing a fluorescent tracer into the water wall tube, collecting a dyeing image of the interior of the water wall tube, generating a dyeing characterization parameter based on the dyeing brightness and the dyeing length obtained by the dyeing image, and judging whether the reason that the water wall tube does not meet the water film forming requirement is accurate or not based on the dyeing characterization parameter; The method comprises the steps of responding to the fact that the water wall pipe does not meet the water film forming requirement is accurate, adjusting pretreatment parameters or adjusting intercepting length based on water film deviation parameters, responding to the fact that the water wall pipe does not meet the water film forming requirement is inaccurate, and adjusting a water film deviation threshold based on dyeing deviation parameters; And in response to the water wall pipe meeting the water film forming requirement, welding the water wall pipe, acquiring the temperature rise rate of the water wall pipe to judge whether the water film thickness is qualified or not, and in response to the water film thickness is unqualified, calculating temperature rise deviation parameters based on the temperature rise rate and the temperature rise rate threshold to adjust the water film characteristic threshold.
2. The process for high-precision welding and processing of a water wall pipe based on real-time temperature control monitoring as claimed in claim 1, wherein the process of dividing the cross section of the water wall pipe into a plurality of welding areas and collecting corresponding detection images to calculate the wall pipe thickness and the wall pipe bevel angle of each welding area respectively comprises the following steps of, Dividing the cross section of the water wall pipe into a plurality of welding areas and collecting detection images corresponding to the welding areas, wherein any one of the welding areas at least comprises a continuous welding section; collecting the thickness of a plurality of wall pipes and the bevel angle of the wall pipes in each welding area; Calculating the average value of the thickness of each wall pipe as a thickness factor corresponding to each welding area; and calculating the average value of the groove angles of the wall pipes as an angle factor corresponding to each welding area.
3. The process for high-precision welding and processing of the water wall tube based on real-time temperature control monitoring according to claim 2, wherein the risk trend of the water wall tube is determined according to the comparison result of the wall tube characterization parameter and the wall tube standard parameter, Determining a weighted sum value of the thickness factor and the angle factor as a wall pipe characterization parameter; the wall pipe deviation parameter is the absolute value of the difference value between the wall pipe characterization parameter and the wall pipe standard parameter; If the wall pipe deviation parameter is larger than or equal to the first wall pipe deviation threshold value and smaller than or equal to the second wall pipe deviation threshold value, judging that the risk trend of the water wall pipe is weak welding risk; And if the wall pipe deviation parameter is smaller than the first wall pipe deviation threshold or larger than the second wall pipe deviation threshold, judging that the risk trend of the water wall pipe is a strong welding risk.
4. The process for high-precision welding processing of water wall tubes based on real-time temperature control monitoring as claimed in claim 3, wherein the process for determining pretreatment parameters and interception length of pre-welding of water wall tubes with strong welding risk according to the comparison result of the characterization parameters of the wall tubes and standard parameters of the wall tubes comprises the following steps of, Determining the pretreatment parameter as the product of the first ratio and the standard pretreatment parameter; determining that the intercepting length is the product of the total length of the strong welding risk water wall pipe and the second ratio; the first ratio is a ratio of the wall pipe characterization parameter to the wall pipe standard parameter, the sum of the second ratio and the ratio of the wall pipe standard parameter to the wall pipe characterization parameter is 1, and the pretreatment parameters comprise welding current and welding speed.
5. The high-precision welding processing technology for the water wall pipe based on real-time temperature control monitoring as claimed in claim 4, wherein the process of calculating the water film characteristic parameters of the single welding running water section based on the temperature of the welded seam infrared image acquisition wall pipe comprises the following steps of, Calculating the difference value between the circumferential minimum wall pipe temperature and the maximum wall pipe temperature of the same welding line as the wall temperature difference; and calculating the standard deviation of the wall temperature differences of a plurality of welding seams as the characteristic parameters of the water film.
6. The high-precision welding process for the water wall tube based on the real-time temperature control monitoring of claim 5, wherein whether the water wall tube meets the water film forming requirement or not is judged based on the water film characteristic parameter, wherein, If the water film characteristic parameter is larger than the water film characteristic threshold, judging that the water wall pipe does not meet the water film forming requirement; And if the water film characteristic parameter is smaller than or equal to the water film characteristic threshold, judging that the water wall pipe meets the water film forming requirement.
7. The process for high-precision welding and processing of water wall tubes based on real-time temperature control monitoring as claimed in claim 6, wherein the process for determining the reason why the water wall tubes do not meet the water film forming requirement based on the water film deviation parameter comprises, Determining the absolute value of the difference value between the water film characteristic parameter and the water film characteristic threshold value as a water film deviation parameter; If the water film deviation parameter is smaller than or equal to the water film deviation threshold value, judging that the water wall pipe does not meet the water film forming requirement because of weld flash at the weld joint; and if the water film deviation parameter is larger than the water film deviation threshold, judging that the water wall pipe does not meet the water film forming requirement because the weld joint is not completely welded.
8. The process for high-precision welding and processing of water wall tubes based on real-time temperature control monitoring as claimed in claim 7, wherein the process of generating dyeing characterization parameters according to dyeing brightness and dyeing length obtained from dyeing images comprises the steps of, Collecting dyeing images at the welding seam, and obtaining dyeing brightness and dyeing length of each dyeing image; Determining the ratio of the average value of a plurality of dyeing brightnesses to the reference dyeing brightness as a brightness factor; determining the ratio of the average value of a plurality of dyeing lengths to the reference dyeing length as a length factor; And determining the weighted summation value of the brightness factor and the length factor as a dyeing characterization parameter.
9. The process for high-precision welding and processing of water wall tubes based on real-time temperature control monitoring as claimed in claim 8, wherein the process is characterized in that whether the reason why the water wall tubes do not meet the water film forming requirement is accurate or not is judged based on dyeing characterization parameters, Under the condition that the weld joint exists in the water wall pipe which does not meet the water film forming requirement, if the dyeing characterization parameter is larger than the dyeing characterization threshold value, judging that the water wall pipe does not meet the water film forming requirement is inaccurate in reason; Under the condition that the water wall pipe does not meet the water film forming requirement and the weld is not completely welded, if the dyeing characterization parameter is smaller than the dyeing characterization threshold value, judging that the water wall pipe does not meet the water film forming requirement is inaccurate.
10. The process for high-precision welding and processing of water wall tubes based on real-time temperature control monitoring as claimed in claim 9, wherein the step of obtaining the temperature rise rate of the water wall tubes to determine whether the water film thickness is acceptable comprises, Setting a plurality of monitoring points outside the water wall pipe, and collecting the initial temperature and the final temperature of each monitoring point at preset time to calculate the temperature difference; calculating the ratio of the temperature difference to the preset time as the temperature rise rate; If the temperature rise rate of any monitoring point is greater than the temperature rise rate threshold, judging that the thickness of the water film is unqualified.

Description

Water wall pipe high-precision welding processing technology based on real-time temperature control monitoring Technical Field The invention relates to the technical field of welding, in particular to a high-precision welding processing technology of a water wall pipe based on real-time temperature control monitoring. Background The utility model provides a water wall pipe as the core pressurized part of power plant boiler, its welding precision directly relates to the safe operation and the life of boiler, welding defect is difficult to discernment in real time and early warning, in the water wall pipe welding process, the formation quality of intraductal water film directly influences welding temperature field stability and welding seam shaping quality, if water film thickness is uneven, discontinuous or lack, can lead to the pipe wall local overheat, the boiling heat transfer aggravates, and then cause pipe wall burn out or welding seam defect aggravation, the risk classification management and control that exists is insufficient in the current water wall pipe welding process, water film quality can't accurate judgement, real-time temperature control is lost and pretreatment parameter adjustment blind scheduling's technical problem, need develop a high accuracy welding process technology based on real-time temperature control monitoring, through accurate subregion detection, risk classification, water film quality closed loop control and real-time parameter adjustment satisfy thermodynamic equipment high efficiency, safety, long-term operation's demand. CN118720333a, the invention provides a welding seam structure and welding process suitable for narrow gap waterwall tube panels, which relates to the technical field of boiler manufacturing, and comprises a groove type gap formed between adjacent waterwall tubes, wherein a welded junction is arranged on one side of each adjacent waterwall tube, which is close to each other, and is distributed on the upper side of the groove type gap, and is communicated with the groove type gap, the groove type gap comprises any one of a V-shaped groove and a U-shaped groove, besides the original welded junction, the adjacent waterwall tubes are taken into consideration as a whole, and are processed into a groove type and welded together with the welded junction, so that the thickness and the safety coefficient of the welding seam at the cut point are increased, the radiographic inspection is facilitated, and the technical problems that when the gap between the adjacent waterwall tubes is small, the welding quality of the cut point position of the adjacent waterwall tubes cannot be effectively ensured due to inconvenient observation, welding and flaw detection are solved, and the potential safety hazard is brought to the safe operation of a unit are solved. The prior art also has the following problems that the heat absorption capacity of the water wall pipe in practical application is detected by analyzing the characteristics of the water film under the condition of heating the water wall pipe, and the welding process is timely adjusted to improve the welding precision aiming at the condition of non-compliance. Disclosure of Invention Therefore, the invention provides a high-precision welding processing technology of a water wall pipe based on real-time temperature control monitoring, which is used for solving the problem that the prior art does not consider that the heat absorption capacity of the water wall pipe in practical application is detected by analyzing the characteristics of a water film under the condition of heating the water wall pipe, and the welding technology is timely adjusted to improve the welding precision aiming at the condition of being out of compliance. In order to achieve the above purpose, the invention provides a water wall pipe high-precision welding processing technology based on real-time temperature control monitoring, comprising the following steps: Dividing the cross section of the water wall pipe into a plurality of welding areas, collecting corresponding detection images, respectively calculating the thickness and the bevel angle of the wall pipe in each welding area, and calculating the characterization parameters of the wall pipe based on the thickness and the bevel angle of the wall pipe; Determining risk trend and pretreatment parameters of the water wall pipe according to the comparison result of the wall pipe characterization parameters and the wall pipe standard parameters, and intercepting length when pre-welding the water wall pipe with strong welding risk; Heating the pre-welded water wall pipe, acquiring a weld infrared image, acquiring a wall pipe temperature based on the weld infrared image, calculating a water film characteristic parameter of a single welding running water section based on the wall pipe temperature, judging whether the water wall pipe meets the water film forming requirement or not, responding to the wate