管道全位置超窄间隙焊机的研制
|
摘要
超窄间隙焊接自身具备的优势用于管道焊接,将有利于国内外管道焊接技术的发展。实验室在超窄间隙焊接中进行了一定的研究,并取得了一定的成果。现希望将该技术用于管道焊接,与企业进行合作,研制一种管道全位置超窄间隙焊机。重点完成弧焊发电机及焊接控制系统的研制。
针对野外管道焊接施工的要求,研制了由汽油机驱动的直流弧焊发电机,其采用三次谐波励磁同步发电机。通过采样焊接电流和焊接电压的瞬时波形,直接通过运算电路得到控制IGBT导通的脉冲信号,用于调节同步发电机的励磁电流,实现了对弧焊发电机的外特性进行快速响应的控制。通过改变焊接电压反馈和焊接电流反馈的深度,实现了弧焊发电机获得下降特性和平特性两种输出。在野外大口径管道焊接中,下降外特性输出用于纤维素焊条电弧焊进行根焊；平特性输出用于超窄间隙自动焊填充及盖面。实验表明,该弧焊发电机外特性响应速度快,焊接参数可连续调节,调节范围可满足实际需求。
根据管道全位置超窄间隙焊接对控制系统的要求,研制了超窄间隙焊接控制系统。该控制系统采用SOC单片机为控制核心,采取分段控制法即对管道分成24段,对每段采取不同的焊接参数。通过该控制系统实现了在不同的焊接位置处,焊接参数的自动调节。另外控制系统还实现了超窄间隙焊机各功能按键及显示系统的控制。控制面板简单、实用、功能齐全、可视化强。控制系统稳定性高,响应速度快。
If the advantage of ultra-narrow gap welding can be used for pipe welding,it will bring about rapid development for pipe welding technology at home and abroad. The ultra-narrow gap welding was carried out some research in our laboratory and some results have been achieved. The technology is hoped applied for pipe welding and a set of pipe all-position ultra-narrow welding machine for field welding is developed. Development arc welding generator and welding control system is focused on.
To meet field pipeline welding requirements, DC arc welding generator by gas oline is developed.The arc welding generator uses third-harmonic excitation synchronous generator. By sampling welding current and welding voltage instantaneous waveform taken as feedback signal, an operational amplifier circuit produces pulse width signal to control IGBT which regulates excitation current of arc welding generator. This control method can improve responding speed of welding variables of arc welding generator to change of arc length. By regulating the feedback depth of welding voltage and welding current, arc welding generator can obtain dropping and constant voltage external characteristics. In the field large diameter pipe welding, dropping external characteristic can be used for root welding by shielded metal arc welding, and constant voltage external characteristic can be used for fill and cap welding by ultra-narrow gas metal arc welding with constant wire feed speed. Experiments show that the external characteristics of arc welding generator response rapidly and the welding parameters can be adjusted Continuously, adjustment range can meet the actual demand.
To meet the requirements of pipe all position ultra-narrow welding for welding control system, welding control system is developed. The control system adopts SOC MCU as core and take segment control method.Pipe is divided into 24 channels and take different welding parameters for each channel. By welding control system, welding parameters is automatic adjustment. In addition, control system can achieve the control of buttons and display system of ultra-narrow gap welding machine. Control panel is simple, practical, functional,visual and intensity. The stability of control system is high and response speed is fast.
针对野外管道焊接施工的要求,研制了由汽油机驱动的直流弧焊发电机,其采用三次谐波励磁同步发电机。通过采样焊接电流和焊接电压的瞬时波形,直接通过运算电路得到控制IGBT导通的脉冲信号,用于调节同步发电机的励磁电流,实现了对弧焊发电机的外特性进行快速响应的控制。通过改变焊接电压反馈和焊接电流反馈的深度,实现了弧焊发电机获得下降特性和平特性两种输出。在野外大口径管道焊接中,下降外特性输出用于纤维素焊条电弧焊进行根焊；平特性输出用于超窄间隙自动焊填充及盖面。实验表明,该弧焊发电机外特性响应速度快,焊接参数可连续调节,调节范围可满足实际需求。
根据管道全位置超窄间隙焊接对控制系统的要求,研制了超窄间隙焊接控制系统。该控制系统采用SOC单片机为控制核心,采取分段控制法即对管道分成24段,对每段采取不同的焊接参数。通过该控制系统实现了在不同的焊接位置处,焊接参数的自动调节。另外控制系统还实现了超窄间隙焊机各功能按键及显示系统的控制。控制面板简单、实用、功能齐全、可视化强。控制系统稳定性高,响应速度快。
If the advantage of ultra-narrow gap welding can be used for pipe welding,it will bring about rapid development for pipe welding technology at home and abroad. The ultra-narrow gap welding was carried out some research in our laboratory and some results have been achieved. The technology is hoped applied for pipe welding and a set of pipe all-position ultra-narrow welding machine for field welding is developed. Development arc welding generator and welding control system is focused on.
To meet field pipeline welding requirements, DC arc welding generator by gas oline is developed.The arc welding generator uses third-harmonic excitation synchronous generator. By sampling welding current and welding voltage instantaneous waveform taken as feedback signal, an operational amplifier circuit produces pulse width signal to control IGBT which regulates excitation current of arc welding generator. This control method can improve responding speed of welding variables of arc welding generator to change of arc length. By regulating the feedback depth of welding voltage and welding current, arc welding generator can obtain dropping and constant voltage external characteristics. In the field large diameter pipe welding, dropping external characteristic can be used for root welding by shielded metal arc welding, and constant voltage external characteristic can be used for fill and cap welding by ultra-narrow gas metal arc welding with constant wire feed speed. Experiments show that the external characteristics of arc welding generator response rapidly and the welding parameters can be adjusted Continuously, adjustment range can meet the actual demand.
To meet the requirements of pipe all position ultra-narrow welding for welding control system, welding control system is developed. The control system adopts SOC MCU as core and take segment control method.Pipe is divided into 24 channels and take different welding parameters for each channel. By welding control system, welding parameters is automatic adjustment. In addition, control system can achieve the control of buttons and display system of ultra-narrow gap welding machine. Control panel is simple, practical, functional,visual and intensity. The stability of control system is high and response speed is fast.
引文
[1]尹士科,王振家译.窄间隙焊接.北京：机械工业出版社,1988：1-30
[2]张富巨,罗传红.窄间隙焊及其新进展.焊接技术,2000,29(6)：33-36
[3]王朋,张富巨.窄间隙焊接技术及其新进展.电力建设,1999(8)：12-14
[4]胡存银,张富巨.窄间隙焊接技术与经济特性分析.2001,30(2)：47-48
[5]宋广贺,王中辉.高压环境下管道焊接技术研究.焊管,2007(3)：18-20
[6]D. Yapp, S. A. Blackman. Recent Developments in High Productivity Pipeline Welding. J.of the Braz. Soc. of Mech. Sci.& Eng,2004(1):89-97
[7]KimJW,NaSJ.A study on arc sensor algorithm for weld seam.Brazilian Manufacturing Congress,1991 (10):247-255
[8]LopesG,YappD. Through the arc sensing pulse GMAW for pipe welding applications.Brazilian Manufacturing Congress,2002(3):42-45.
[9]HurJW,KimJW,NaSJ.A study on seam tracking with an arc signal in GMAW With maxed gas. Brazilian Manufacturing Congress,2004(5):21-25
[10]KoenFaes,AlfredDhooge.Parameter optimisation for automatic pipeline girth welding using a new friction welding method. Materials and Design,2008(3):45-50
[11]M.D.Chapetti,J.L.Otegui,J.Motylicki. Fatigue assessment of an electrical resistance welded oil pipeline. International Journal of Fatigue,2004(24):21-28
[12]Hyeong-SoonMoon, Sung-HoonKo,Jeong-CheolKim.Automatic seam tracking in pipeline welding with narrow groove. Int J Adv Technol,2008(10): 12-16
[13]Ario Suanar BASKORO, Masashi KABUTOMORI,Yasuo SUGA.Automatic Welding System of Aluminum pipe by Monitoring Backside Image of Molten pool Using Vision Sensor. Journal Of Solid Mechanics and Materials Engineering,2008(5):582-592
[14]胡安鑫,苏欣,孙华锋,等.国内外长输管道自动焊现状.天然气与石油,2006(4)：12-18
[15]于英姿.自动焊技术在长输管道焊接中的应用.焊管,2001,24(2):47-55
[16]薛振奎.我国油气管道和焊接技术.焊接,2002(11):11-14
[17]闫政 梁君直 陈江.PAW2000管道全位置自动焊机.电焊机,2005(6)：47-53
[18]刘成玉,许先果,赵建华,等.长输管道焊接方法的选择与应用.电焊机,2007(11)：58-59
[19]刘必利,谢颂京,姚建华.激光技术应用及发展趋势.激光与光电子学进展,2005(9)：43-47
[20]Claus Thmomy,Thomas Seefeld. Application of Fiber Lasers to Pipeline Girth Welding. Welding Journal,2006(7):54-58
[21]郭瑞杰,付桂英,杨天冰,等.长输油气管道激光焊接技术.电焊机,2007,37(11)：15-17
[22]章亚林,张富巨.电站大直径厚壁管全位置半自动FCAW工艺研究.电力建设,1999(4)：10-13
[23]GS.Render,B.Sc.Meng,Mweldl.Welding advantages in power plant Narrow gap welding. Metal construction,1984(11):11-15
[24]GE.Cook and P.C.Leviek. Narrow Gap Welding with the Hot Wire GTA Process. Welding Journal,1985(8):27-32
[25]Terumi NAKAMURA,Kazuo HIRAOK,Chiaki SHIGA.Development of Ultra-Narrow Gap GMA Welding Process.Recent Technology of Welding in Vessel and Pipe,2000:111-116
[26]那雪冬,朱亮.细晶粒钢的涂覆焊剂片超窄间隙焊.电焊机,2004,34(8)：20-23
[27]Z.Masysumiya,M.Kawahara,M.Yakao, et al.Development of orbital Narrow Gap GTA Welding equipment and application to main steam pipes of boilers. Technical commission on weldingprocesses,SW-1 645-85,1985
[28]T.Takuwa,Ykondou,K.Mistsuhata.Development of orbital Narrow-GapHSTig Welding equipment and application to main steam pipes of boilers.Technical commission on welding processes,SW-2333-94,1994
[29]李午申.我国合金结构钢的新发展及其焊接性.焊接学报,2001,22(5)：82-87
[30]彭云,王成.两种规格超细晶粒钢的激光焊.焊接学报,2001,22(2)：31-35
[31]宋洪伟.微米、亚微米与纳米超细晶粒钢的研究进展.世界科技研究与发展,2004(5)：31-35
[32]宋立秋,侯豁然.超细晶粒钢的显微组织.钢铁钒钛,2003,24(3)：32-36
[33]王成,张旭东.超细晶粒钢激光焊接HAZ晶粒长大的数学模型及实验研究.应用激光,2002,22(2)：181-184
[34]董瀚.超细晶粒钢及其力学性能特征.中国冶金,2003(10)：26-31
[35]盖志武,戴景民.发电电焊机及其控制系统设计与分析.焊接学报,2005,26 (7)：23-26
[36]郑宜庭,黄石生.弧焊电源.北京：机械工业出版社,2004：155-158
[37]都东,韩赞东,张前,等.弧焊逆变器输出电流本脉冲反馈控制.焊接学报,1997,18(3)：166-170
[38]苏欣,袁宗明,范小霞,等.管道焊接工艺方法综述.管道技术与设备,2005(6)：35-37,40
[39]郑照东.纤维素焊条向下焊打底、自保护药芯半自动焊填充盖面焊接技术.焊接,2000(5)：39-40
[40]Zhu Zhengqiang,Chen Ligong,Xu Jianning, et al.Modeling and estimating for external.characteristic of welding power source.International Journal of Advanced Manufacturing Technology,2006(29):269-272
[41]马庆伟.供热管道纤维素焊条下向焊焊接技术分析.机械研究与应用,2008,21(4)：26-27
[42]李宪政.“下向焊”工艺方法在管道焊接中的应用及设备特点.电焊机,1999,29(4)：23-24,28
[43]王永锋,朱亮.交流发电直流弧焊两用机组的研究.电焊机,2001,31(11)：25-27
[44]邱明,张曙明,曲金泽.两种新型实用直流无刷电机控制器的设计与实现.电子技术应用,2006(10)：77-79
[45]李颖宏.单片机在直流无刷电机驱动器中的应用.中国仪器仪表,2001(4)：35-36
[46]张俊谟.SOC单片机原理与应用——基于C8051F系列.北京：北京航空航天大学出版社,2007：1-12
[47]万光毅,孙万九,蔡建平.SOC单片机实验,实践与应用设计基——于C8051F系列.北京：北京航空航天大学出版社,2006：1-45
[48]杨应平,石城,蒋爱湘,等.图形点阵液晶显示模块与51系列单片机的接口设计.现代显示,2006(5)：41-45
[49]洪家平.中文图形显示控制芯片ST7920的原理与应用.国外电子元器件,2005(1)：38-40
[50]苏少钰,左兵城,姜剑芳.基于ARM7微处理器的中文液晶显示技术.现代电子技术,2006(18)：22-24
[2]张富巨,罗传红.窄间隙焊及其新进展.焊接技术,2000,29(6)：33-36
[3]王朋,张富巨.窄间隙焊接技术及其新进展.电力建设,1999(8)：12-14
[4]胡存银,张富巨.窄间隙焊接技术与经济特性分析.2001,30(2)：47-48
[5]宋广贺,王中辉.高压环境下管道焊接技术研究.焊管,2007(3)：18-20
[6]D. Yapp, S. A. Blackman. Recent Developments in High Productivity Pipeline Welding. J.of the Braz. Soc. of Mech. Sci.& Eng,2004(1):89-97
[7]KimJW,NaSJ.A study on arc sensor algorithm for weld seam.Brazilian Manufacturing Congress,1991 (10):247-255
[8]LopesG,YappD. Through the arc sensing pulse GMAW for pipe welding applications.Brazilian Manufacturing Congress,2002(3):42-45.
[9]HurJW,KimJW,NaSJ.A study on seam tracking with an arc signal in GMAW With maxed gas. Brazilian Manufacturing Congress,2004(5):21-25
[10]KoenFaes,AlfredDhooge.Parameter optimisation for automatic pipeline girth welding using a new friction welding method. Materials and Design,2008(3):45-50
[11]M.D.Chapetti,J.L.Otegui,J.Motylicki. Fatigue assessment of an electrical resistance welded oil pipeline. International Journal of Fatigue,2004(24):21-28
[12]Hyeong-SoonMoon, Sung-HoonKo,Jeong-CheolKim.Automatic seam tracking in pipeline welding with narrow groove. Int J Adv Technol,2008(10): 12-16
[13]Ario Suanar BASKORO, Masashi KABUTOMORI,Yasuo SUGA.Automatic Welding System of Aluminum pipe by Monitoring Backside Image of Molten pool Using Vision Sensor. Journal Of Solid Mechanics and Materials Engineering,2008(5):582-592
[14]胡安鑫,苏欣,孙华锋,等.国内外长输管道自动焊现状.天然气与石油,2006(4)：12-18
[15]于英姿.自动焊技术在长输管道焊接中的应用.焊管,2001,24(2):47-55
[16]薛振奎.我国油气管道和焊接技术.焊接,2002(11):11-14
[17]闫政 梁君直 陈江.PAW2000管道全位置自动焊机.电焊机,2005(6)：47-53
[18]刘成玉,许先果,赵建华,等.长输管道焊接方法的选择与应用.电焊机,2007(11)：58-59
[19]刘必利,谢颂京,姚建华.激光技术应用及发展趋势.激光与光电子学进展,2005(9)：43-47
[20]Claus Thmomy,Thomas Seefeld. Application of Fiber Lasers to Pipeline Girth Welding. Welding Journal,2006(7):54-58
[21]郭瑞杰,付桂英,杨天冰,等.长输油气管道激光焊接技术.电焊机,2007,37(11)：15-17
[22]章亚林,张富巨.电站大直径厚壁管全位置半自动FCAW工艺研究.电力建设,1999(4)：10-13
[23]GS.Render,B.Sc.Meng,Mweldl.Welding advantages in power plant Narrow gap welding. Metal construction,1984(11):11-15
[24]GE.Cook and P.C.Leviek. Narrow Gap Welding with the Hot Wire GTA Process. Welding Journal,1985(8):27-32
[25]Terumi NAKAMURA,Kazuo HIRAOK,Chiaki SHIGA.Development of Ultra-Narrow Gap GMA Welding Process.Recent Technology of Welding in Vessel and Pipe,2000:111-116
[26]那雪冬,朱亮.细晶粒钢的涂覆焊剂片超窄间隙焊.电焊机,2004,34(8)：20-23
[27]Z.Masysumiya,M.Kawahara,M.Yakao, et al.Development of orbital Narrow Gap GTA Welding equipment and application to main steam pipes of boilers. Technical commission on weldingprocesses,SW-1 645-85,1985
[28]T.Takuwa,Ykondou,K.Mistsuhata.Development of orbital Narrow-GapHSTig Welding equipment and application to main steam pipes of boilers.Technical commission on welding processes,SW-2333-94,1994
[29]李午申.我国合金结构钢的新发展及其焊接性.焊接学报,2001,22(5)：82-87
[30]彭云,王成.两种规格超细晶粒钢的激光焊.焊接学报,2001,22(2)：31-35
[31]宋洪伟.微米、亚微米与纳米超细晶粒钢的研究进展.世界科技研究与发展,2004(5)：31-35
[32]宋立秋,侯豁然.超细晶粒钢的显微组织.钢铁钒钛,2003,24(3)：32-36
[33]王成,张旭东.超细晶粒钢激光焊接HAZ晶粒长大的数学模型及实验研究.应用激光,2002,22(2)：181-184
[34]董瀚.超细晶粒钢及其力学性能特征.中国冶金,2003(10)：26-31
[35]盖志武,戴景民.发电电焊机及其控制系统设计与分析.焊接学报,2005,26 (7)：23-26
[36]郑宜庭,黄石生.弧焊电源.北京：机械工业出版社,2004：155-158
[37]都东,韩赞东,张前,等.弧焊逆变器输出电流本脉冲反馈控制.焊接学报,1997,18(3)：166-170
[38]苏欣,袁宗明,范小霞,等.管道焊接工艺方法综述.管道技术与设备,2005(6)：35-37,40
[39]郑照东.纤维素焊条向下焊打底、自保护药芯半自动焊填充盖面焊接技术.焊接,2000(5)：39-40
[40]Zhu Zhengqiang,Chen Ligong,Xu Jianning, et al.Modeling and estimating for external.characteristic of welding power source.International Journal of Advanced Manufacturing Technology,2006(29):269-272
[41]马庆伟.供热管道纤维素焊条下向焊焊接技术分析.机械研究与应用,2008,21(4)：26-27
[42]李宪政.“下向焊”工艺方法在管道焊接中的应用及设备特点.电焊机,1999,29(4)：23-24,28
[43]王永锋,朱亮.交流发电直流弧焊两用机组的研究.电焊机,2001,31(11)：25-27
[44]邱明,张曙明,曲金泽.两种新型实用直流无刷电机控制器的设计与实现.电子技术应用,2006(10)：77-79
[45]李颖宏.单片机在直流无刷电机驱动器中的应用.中国仪器仪表,2001(4)：35-36
[46]张俊谟.SOC单片机原理与应用——基于C8051F系列.北京：北京航空航天大学出版社,2007：1-12
[47]万光毅,孙万九,蔡建平.SOC单片机实验,实践与应用设计基——于C8051F系列.北京：北京航空航天大学出版社,2006：1-45
[48]杨应平,石城,蒋爱湘,等.图形点阵液晶显示模块与51系列单片机的接口设计.现代显示,2006(5)：41-45
[49]洪家平.中文图形显示控制芯片ST7920的原理与应用.国外电子元器件,2005(1)：38-40
[50]苏少钰,左兵城,姜剑芳.基于ARM7微处理器的中文液晶显示技术.现代电子技术,2006(18)：22-24