Research On Automatic Submerged Arc Welding Remote Adjustment And Welding Parameter Monitoring

Submerged arc automatic welding is the main welding method in the production of large pressure vessels.The arc of the welding method is buried under the flux layer for combustion.The welding method has the advantages of high welding productivity and stable welding quality.Welding torch adjustment work needs to be done manually in most pressure vessel manufacturers.This kind of working mode has the disadvantages of high labor intensity,high risk,poor working conditions and low efficiency.Parameters such as welding current and arc voltage affect welding quality.Excessive energy of the welding line causes coarse grain in the superheated zone,which is the main cause of premature cracking in pressure vessels.This thesis introduces the design of remote control and welding parameter acquisition device for submerged arc automatic welding.This device is designed based on the existing submerged arc welding machine for the problem of pressure vessel welding process.The remote adjusting device of welding torch consists of mechanical structure and control system.The mechanical structure is divided into a visual mechanism,an actuator,a welding mechanism,and a control box.The industrial camera captures the image information of the welding process,and the pan-tilt adjusts the position of the camera in the visual mechanism.The actuator is a cross-shaped structure composed of two linear screw slide modules.The ball screw structure of the module converts the stepping motor rotation into linear motion of the slide table.Welding mechanism consists of welding machine head,welding power supply,wire feeding mechanism,etc.The control box is composed of the box and various electrical components,which is the guarantee of the movement of the device.The control system includes three modules:torch position adjustment control,pan-tilt servo control and video monitoring.The software of video monitoring displays image information captured by the camera.The software of torch position adjustment control module sends a control command to the motion control card,the motion control card sends a pulse and direction signal to the driver,and the driver drives the stepper motor motion.The software of pan-tilt servo control module sends control commands to the Arduino driver board,and the drive board drives the steering gear to rotate.The welding parameter acquisition device can collect and process the welding current and arc voltage parameters,and has an early warning function.The working process of the device is as follows:The power transmitter converts the electrical signal into an analog signal input to the data acquisition card.The data acquisition card amplifies and filters the analog signal and converts it into an electrical signal input to the upper computer.The upper computer software displays and records the voltage and current data.If the parameter fluctuates abnormally,the software will give an alarm reminder.The virtual prototype technology was used to simulate the submerged arc automatic welding remote adjustment device through ADAMS software.The simulation results show the torch speed curve and the stepper motor drive torque curve.Make a prototype of the device and test the remote position adjustment movement of the welding torch and the welding current and voltage parameter acquisition function.Simulation and testing provide the basis for further optimizing the mechanical structure and hardware and software design of the device.The submerged arc automatic welding remote adjusting and the welding parameter acquisition device solve the problems of low efficiency,poor labor environment and inaccurate and easy omission of manually recorded welding parameter data.It reduce the burden on the worker.In actual production,this device can greatly improve production efficiency and economic benefits and has a good application prospect.