Control System Design And Analysis On Process Parameter Of Water-wall Automatic Cladding Machine

Abrasion problems of circulating fluidized bed(CFB) of boiler water wall have serious effect on the service life of boiler,which restricts the development of critical and over-critical boilers. While the anti-abrasion technology of traditional water wall technology has many kinds of disadvantages, such as short service life, bad stability, it has higher requirement for internal wall construction of water wall. The emergence of hard metal welding technology on the surface of water wall can overcome the disadvantages of traditional anti-abrasion technology; it can increase the service life of water wall pipe of boiler from 5 to 6 years, so the development of a set of alloy welding machine has become the difficult problems that boiler company, power plant, heat-supply company, chemical enterprise etc need to resolve.This thesis firstly introduces the usage state and abrasion mechanism of boiler water wall of CFB, it illustrates the merit and advantage of superficial hard alloy welding,investigates research state of welding machine both in China and abroad, it also designs develops one set of welding machine system with the highest atomization and high intelligence on this basis, including wall-mounted robot system, welding power assembly,monitoring system etc, which can meet a series of requirements in the welding process water wall surface.Through the dynamics analysis and calculation, we get the mechanical system of inertia and the applied load, thus we select the drive motor. Through movement request,the paper selects and designs the corresponding numerical control and detection system,and then conducts the system integration, build the complete control system.Meanwhile it designs one set of complete automatic control procedure for machine during working, including automatic welding, manual commissioning, information collection and procession, self-plan and self-location of weld bead, human-computer interaction, in addition, it can establish space deviation model of welding machine,provides reference for enforcement agencies at the end of welding torch and accurate positioning. Its characteristics are able to automatically complete straight pipe, welded elbow and guide-tube deposition, Can automatically complete the water cooler relative deposition position detection, automatic generation of deposition path planning .In view of the particularity of process and welding wire, it proposes the idea of superficial welding process and carries out demonstrate test for water wall pipe according to test standard, it finds and formulates 92 groups of formed process standard under different influential factors such as voltage, current, wire rate, welding speed, swing pattern etc as well as introduces idea of double-wire welding. It has completed one set of double-torch and double-wire agencies suitable for welding process by learning reference from Tandem and Time-twin.Finally, it carries out systematic test demonstration for welding machine and completes 5 32 sets of welding machine in buck of 5 models. It has implemented construction in big power plant and chemical enterprise and the time for stable operation is 2160 hours and fault rate is less than 5%.