全数字控制的大口径双焊炬管道全位置自动焊机研究
摘要
针对管道施工中，目前使用的管道焊接设备及采用的焊接工艺方法影响了管道施工的质量和效率。本文以提高焊接效率和焊接质量为目标，研究了一种全新的双焊炬管道全位置自动焊机的结构、控制设计方案，并对单面焊双面成形工艺进行了深入的研究。
机械结构：
机械系统主要由焊接小车行走驱动机构（包括焊接小车、偏心式自动锁紧行
走机构）、送丝部分、焊枪摆动部分、焊枪姿态调整等部分组成，完成焊接过程中所有动作的机构支持。机械结构的设计充分体现了控制方式的完美以及机电相互间的协调匹配。
控制系统：
利用DSP（高速数字信号处理器）的高速信号处理能力和CPLD（复杂可编程逻辑器件）的高密度硬件逻辑结构，研制体积小、集成度高的专用数字运动控制器。
采用PDA（掌上电脑，）作为硬件编程工具，Palm OS嵌入操作系统作为软件平台，C语言作为软件开发工具，研制一种实现焊接参数和控制参数预置、修改及下载的编辑器。
采用汇编语言或ANSI C语言编写运动控制软件和双焊炬焊接工艺软件，其中多轴数字PID算法和三次样条插值算法是软件的重点。
焊接工艺：
研制一种专用控制接口，该接口与焊接电源（根焊专用焊接电源以及通用焊接电源）配合，有效控制熔滴过渡和线能量输入，保证单面焊双面成形工艺的实施。这是单面焊双面成形工艺成败的关键。
双焊炬自动焊工艺应包括双层叠焊、单层排焊和单面焊双面成形根焊。在工艺研究中，重点应放在焊缝成型、焊缝力学性能及单面焊双面成形根焊三个方面。特别要研究总结在不同管口组对精度条件下，实施单面焊双面成形根焊的技术和工艺效果。实现的目标是：在现场可实现的管口组对精度条件下，实施单面焊双面成形根焊的技术条件与工艺方法。
通过对双焊炬管道全位置自动焊机的试验，双焊炬管道全位置自动焊机从根本上解决了厚管壁、V型口的焊接难题。采用双焊炬管道全位置自动焊机叠焊和排焊，有效的提高了焊接速度和效率。整个系统具有自诊和信息检测功能，能动态显示焊接过程中的电位、电压、焊接速度。
双焊炬管道全位置自动焊机所具有的技术优势必然推动焊接技术的发展，将会创造很高的社会效益和经济效益。
In pipeline construction, now, the welding technique of adopting and the pipeline welding equipment of use has affected efficiency and the quality of pipeline construction. This paper is taking raising welding efficiency and welding quality as goal , has offered a kind of dual torch external welding machine, control design scheme of welding torch pipeline completely location automatic welder , and for sheet surface weld two-sided shape technology have carried out thorough research.
1. Mechanical structure of dual torch external welding machine :
The overall structural Electromechanical unifinication that has carried out system is designed. It is of actuating device that mechanical system walk mainly from welding pushcart ( include welding machine and automatic locking walk system ) , wire speed part and the partof welding torch swing , and posture adjustments of welding torch. To sustains all movements by the structure in complete welding course. The design of mechanical structure has embodied the coordination between each other of Electromechanical as well as the perfect of control way fully to match.
2. Control system of dual torch external welding machine:
1 ) handle ability and the degree hardware logic structure of high density of CPLD ( complex but programming logic device ) using the high speed signal of DSP ( with high speed digital signal processor ), the volume of R&D is little , the digital sport controler for special purpose of high integrated degree.
2 ) adopt PDA ( palmtop computer, ) as hardware programming tool, built-in operating system of Palm OS is software platform, C language is software development tool, develop a kind of realization welding parameter and control parameter the editor ware that is put and modified in advance and is downloaded.
3 ) with assembly language or the language of ANSI C, compile sport control software and pair to weld torch welding technology software , is the focal point of software in which the word PID algorithm and three times batten interpolation algorithm of number of axle.
3. Welding technology of dual torch external welding machine:
1 ) develop a kind of control interface for special purpose, this interface and the welding( root weld the welding power source as well as general welding power source for special purpose) coordination of power source, control efficiently Rong drop transitional and line energy input, guarantee single surface to weld the enforcement of two-sided shape technology. This is single surface weld the key of
two-sided shape technology success or failure.
2 ) pair welds first voluntarily welder skill, should include double-deck layer upon layer 0to weld , monolayer row weld with single surface weld two-sided shape root weld. In technology research focal point should put in weld become type, weld mechanics performance and single surface weld two-sided shape root weld 3 aspects. Will study summary especially in different orifice group for precision condition take off , implement single surface to weld the two-sided shape technical and technology effect of welding thoroughly. The goal of realization is: In scene, the orifice group that can realize implements single surface for precision condition to weld the two-sided shape technical condition and technique that welded thoroughly.
Through welding experiment of dual torch external welders of pipeline, dual torch external welders of pipeline completely location automatic welder, have solved the welding baffling problem of thick tube wall and the mouth of V model from foundation. With pair weld first layer upon layer to weld and get typeset weld , it is effective to have raised welding speed and efficiency. Through last position machine, it is simple and convenient to be able to operate according to actual condition modification welding parameter. Entire system have from examine with information detection function, can development show welding speed, voltage and the potential in welding course.
The technical advantage that pair has for welding torch pipeline completely l
机械结构：
机械系统主要由焊接小车行走驱动机构（包括焊接小车、偏心式自动锁紧行
走机构）、送丝部分、焊枪摆动部分、焊枪姿态调整等部分组成，完成焊接过程中所有动作的机构支持。机械结构的设计充分体现了控制方式的完美以及机电相互间的协调匹配。
控制系统：
利用DSP（高速数字信号处理器）的高速信号处理能力和CPLD（复杂可编程逻辑器件）的高密度硬件逻辑结构，研制体积小、集成度高的专用数字运动控制器。
采用PDA（掌上电脑，）作为硬件编程工具，Palm OS嵌入操作系统作为软件平台，C语言作为软件开发工具，研制一种实现焊接参数和控制参数预置、修改及下载的编辑器。
采用汇编语言或ANSI C语言编写运动控制软件和双焊炬焊接工艺软件，其中多轴数字PID算法和三次样条插值算法是软件的重点。
焊接工艺：
研制一种专用控制接口，该接口与焊接电源（根焊专用焊接电源以及通用焊接电源）配合，有效控制熔滴过渡和线能量输入，保证单面焊双面成形工艺的实施。这是单面焊双面成形工艺成败的关键。
双焊炬自动焊工艺应包括双层叠焊、单层排焊和单面焊双面成形根焊。在工艺研究中，重点应放在焊缝成型、焊缝力学性能及单面焊双面成形根焊三个方面。特别要研究总结在不同管口组对精度条件下，实施单面焊双面成形根焊的技术和工艺效果。实现的目标是：在现场可实现的管口组对精度条件下，实施单面焊双面成形根焊的技术条件与工艺方法。
通过对双焊炬管道全位置自动焊机的试验，双焊炬管道全位置自动焊机从根本上解决了厚管壁、V型口的焊接难题。采用双焊炬管道全位置自动焊机叠焊和排焊，有效的提高了焊接速度和效率。整个系统具有自诊和信息检测功能，能动态显示焊接过程中的电位、电压、焊接速度。
双焊炬管道全位置自动焊机所具有的技术优势必然推动焊接技术的发展，将会创造很高的社会效益和经济效益。
In pipeline construction, now, the welding technique of adopting and the pipeline welding equipment of use has affected efficiency and the quality of pipeline construction. This paper is taking raising welding efficiency and welding quality as goal , has offered a kind of dual torch external welding machine, control design scheme of welding torch pipeline completely location automatic welder , and for sheet surface weld two-sided shape technology have carried out thorough research.
1. Mechanical structure of dual torch external welding machine :
The overall structural Electromechanical unifinication that has carried out system is designed. It is of actuating device that mechanical system walk mainly from welding pushcart ( include welding machine and automatic locking walk system ) , wire speed part and the partof welding torch swing , and posture adjustments of welding torch. To sustains all movements by the structure in complete welding course. The design of mechanical structure has embodied the coordination between each other of Electromechanical as well as the perfect of control way fully to match.
2. Control system of dual torch external welding machine:
1 ) handle ability and the degree hardware logic structure of high density of CPLD ( complex but programming logic device ) using the high speed signal of DSP ( with high speed digital signal processor ), the volume of R&D is little , the digital sport controler for special purpose of high integrated degree.
2 ) adopt PDA ( palmtop computer, ) as hardware programming tool, built-in operating system of Palm OS is software platform, C language is software development tool, develop a kind of realization welding parameter and control parameter the editor ware that is put and modified in advance and is downloaded.
3 ) with assembly language or the language of ANSI C, compile sport control software and pair to weld torch welding technology software , is the focal point of software in which the word PID algorithm and three times batten interpolation algorithm of number of axle.
3. Welding technology of dual torch external welding machine:
1 ) develop a kind of control interface for special purpose, this interface and the welding( root weld the welding power source as well as general welding power source for special purpose) coordination of power source, control efficiently Rong drop transitional and line energy input, guarantee single surface to weld the enforcement of two-sided shape technology. This is single surface weld the key of
two-sided shape technology success or failure.
2 ) pair welds first voluntarily welder skill, should include double-deck layer upon layer 0to weld , monolayer row weld with single surface weld two-sided shape root weld. In technology research focal point should put in weld become type, weld mechanics performance and single surface weld two-sided shape root weld 3 aspects. Will study summary especially in different orifice group for precision condition take off , implement single surface to weld the two-sided shape technical and technology effect of welding thoroughly. The goal of realization is: In scene, the orifice group that can realize implements single surface for precision condition to weld the two-sided shape technical condition and technique that welded thoroughly.
Through welding experiment of dual torch external welders of pipeline, dual torch external welders of pipeline completely location automatic welder, have solved the welding baffling problem of thick tube wall and the mouth of V model from foundation. With pair weld first layer upon layer to weld and get typeset weld , it is effective to have raised welding speed and efficiency. Through last position machine, it is simple and convenient to be able to operate according to actual condition modification welding parameter. Entire system have from examine with information detection function, can development show welding speed, voltage and the potential in welding course.
The technical advantage that pair has for welding torch pipeline completely l
引文
1 长输管道全位置自动焊接设备及配套技术的研究，油气地面工程科技成果专
辑，黑龙江科学技术出版社，2002
2曾惠林、闫政，非旋转管道环焊缝自动化焊接技术及设备研究，管道科学研究
论文选集（1999-2003），石油工业出版社，2003
3夏欣、韩翔宇，闪光焊接技术的发展及在管道建设中的应用，管道科学研究论
文选集（1999-2003），石油工业出版社，2003
4 The better dual torch equipment.，vermaat-technics，2004
5 SERIMER DASA AUTOMATIC PIPELINE WELDING SYSTEM，2001
6 陈朋超、闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道
科学研究论文选集（1999-2003），石油工业出版社，2003
7曾惠林 黄福祥，管道全位置自动焊接技术，油气储运，1999
8张峰、黄鹤、张广齐，管道全自动外焊机焊接工艺，2002石油天然气管道建设与技术论坛会论文集，石油工业出版社，2002
9 机电一体化设计，机械工业出版社，2001
10 机电一体化设计，机械工业出版社，2001
11机电一体化设计，机械工业出版社，2001
12 USA Automatic welding for offshore project，pipes & pipelines International，
2003
13杨可桢、程光蕴，机械设计基础，北京：高等教育出版社，1995，2～3页
14中国石油天然气管道局，管道全位置自动焊机技术规范，中国石油天然气管
道局企业标准，Q/CNPC-GD 0237-2001，2001
15 闫政、曾惠林，管道全位置自动焊机技术规范，中国石油天然气管道局企业
标准，Q/CNPC-GD 0237-2001，2001
16 贾亚洲，机电一体化设计，机械工业出版社，2001
17 周霖，DSP系统设计与实现，国防工业出版社，2003年
18 崔元明编，可编程器件应用导论，北京：清华出版社，2001
19 李冬青，管道全位置自动焊机的分布式计算机控制系统，哈尔滨工业大学学
报，1998(9)
20 吴祖育、秦鹏飞，数控机床，上海科学技术出版社，1990，13～14页
21 陈鹏超、闫政，可编程逻辑器件（CPLD）在管道全位置自动焊机中的应用，2002石油天然气管道建设与技术论坛会论文集，石油工业出版社，2002
22 周霖，DSP系统设计与实现，国防工业出版社，2003年，36～40页
23陈鹏超、闫政，可编程逻辑器件（CPLD）在管道全位置自动焊机中的应用，2002石油天然气管道建设与技术论坛会论文集，石油工业出版社，2002
24 Method of operation for high speed automic welding，United States Patent，October 22，1992
25 陈朋超、闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道
科学研究论文选集（1999-2003），石油工业出版社，2003
26 Distributed processing control system for automic welding operation，United States Patent，September 15，1992
27 周霖，DSP系统设计与实现，国防工业出版社，2003年，18～24页
28 曾繁泰、侯亚宁，崔元明编著，可编程器件应用导论，北京：清华出版社，
2001
29 Lattice Data book，1999
30都东、李先耀、张人豪，IGBT弧焊逆变器反馈控制系统的研究，清华大学，
第八次全国焊接会议论文集（第三册），中国机械工程学会焊接学会，机械
工业出版社
31闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道科学研究
论文选集(1999-2003)，石油工业出版社，2004
32闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道科学研究
论文选集(1999-2003)，石油工业出版社，2004
33 姜焕中，焊接方法及设备，北京：机械工业出版社，1981
34 Development of highly efficient and fully automatic delding （GMAW）for pipeline，Sumitomo Metals，Apr 1998
35 王伟、薛龙，全位置管道自动焊接设备的研究，管道技术与备，2002(4)
辑，黑龙江科学技术出版社，2002
2曾惠林、闫政，非旋转管道环焊缝自动化焊接技术及设备研究，管道科学研究
论文选集（1999-2003），石油工业出版社，2003
3夏欣、韩翔宇，闪光焊接技术的发展及在管道建设中的应用，管道科学研究论
文选集（1999-2003），石油工业出版社，2003
4 The better dual torch equipment.，vermaat-technics，2004
5 SERIMER DASA AUTOMATIC PIPELINE WELDING SYSTEM，2001
6 陈朋超、闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道
科学研究论文选集（1999-2003），石油工业出版社，2003
7曾惠林 黄福祥，管道全位置自动焊接技术，油气储运，1999
8张峰、黄鹤、张广齐，管道全自动外焊机焊接工艺，2002石油天然气管道建设与技术论坛会论文集，石油工业出版社，2002
9 机电一体化设计，机械工业出版社，2001
10 机电一体化设计，机械工业出版社，2001
11机电一体化设计，机械工业出版社，2001
12 USA Automatic welding for offshore project，pipes & pipelines International，
2003
13杨可桢、程光蕴，机械设计基础，北京：高等教育出版社，1995，2～3页
14中国石油天然气管道局，管道全位置自动焊机技术规范，中国石油天然气管
道局企业标准，Q/CNPC-GD 0237-2001，2001
15 闫政、曾惠林，管道全位置自动焊机技术规范，中国石油天然气管道局企业
标准，Q/CNPC-GD 0237-2001，2001
16 贾亚洲，机电一体化设计，机械工业出版社，2001
17 周霖，DSP系统设计与实现，国防工业出版社，2003年
18 崔元明编，可编程器件应用导论，北京：清华出版社，2001
19 李冬青，管道全位置自动焊机的分布式计算机控制系统，哈尔滨工业大学学
报，1998(9)
20 吴祖育、秦鹏飞，数控机床，上海科学技术出版社，1990，13～14页
21 陈鹏超、闫政，可编程逻辑器件（CPLD）在管道全位置自动焊机中的应用，2002石油天然气管道建设与技术论坛会论文集，石油工业出版社，2002
22 周霖，DSP系统设计与实现，国防工业出版社，2003年，36～40页
23陈鹏超、闫政，可编程逻辑器件（CPLD）在管道全位置自动焊机中的应用，2002石油天然气管道建设与技术论坛会论文集，石油工业出版社，2002
24 Method of operation for high speed automic welding，United States Patent，October 22，1992
25 陈朋超、闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道
科学研究论文选集（1999-2003），石油工业出版社，2003
26 Distributed processing control system for automic welding operation，United States Patent，September 15，1992
27 周霖，DSP系统设计与实现，国防工业出版社，2003年，18～24页
28 曾繁泰、侯亚宁，崔元明编著，可编程器件应用导论，北京：清华出版社，
2001
29 Lattice Data book，1999
30都东、李先耀、张人豪，IGBT弧焊逆变器反馈控制系统的研究，清华大学，
第八次全国焊接会议论文集（第三册），中国机械工程学会焊接学会，机械
工业出版社
31闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道科学研究
论文选集(1999-2003)，石油工业出版社，2004
32闫政、梁君直，PAW2000管道全位置自动焊机的研制及应用，管道科学研究
论文选集(1999-2003)，石油工业出版社，2004
33 姜焕中，焊接方法及设备，北京：机械工业出版社，1981
34 Development of highly efficient and fully automatic delding （GMAW）for pipeline，Sumitomo Metals，Apr 1998
35 王伟、薛龙，全位置管道自动焊接设备的研究，管道技术与备，2002(4)