Development and Process Experiments of Automatic Welding Mechanism for SMAW Suitable for Groove Welding inside the Pressure Chamber

HUANG Jiangzhong; LI Lianbo; WANG Fengrui; WANG Haiyang; SU Yanfu; HAO Liya; WANG Zhijiang; WANG Xian

doi:10.7512/j.issn.1001-2303.2025.11.06

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Development and Process Experiments of Automatic Welding Mechanism for SMAW Suitable for Groove Welding inside the Pressure Chamber
Vol. 55, Issue 11, Pages: 37-43(2025)
Received：05 September 2024，

Revised：2025-02-19，

Published：20 November 2025
DOI： 10.7512/j.issn.1001-2303.2025.11.06
稿件说明：

移动端阅览

黄江中，李连波，王凤瑞，等.压力舱内适于坡口焊接的焊条自动焊接装置研制与工艺验证［J］.电焊机，2025，55（11）：37-43. DOI： 10.7512/j.issn.1001-2303.2025.11.06.

HUANG Jiangzhong, LI Lianbo, WANG Fengrui, et al.Development and Process Experiments of Automatic Welding Mechanism for SMAW Suitable for Groove Welding inside the Pressure Chamber[J].Electric Welding Machine, 2025, 55(11): 37-43. DOI： 10.7512/j.issn.1001-2303.2025.11.06.

摘要

为有效探索水下局部干法焊条电弧焊（SMAW）工艺，解决高压环境下焊接试验对专用设备的需求，研制了一套可在压力舱内实现平、横、立、仰多位置焊接的焊条自动焊接装置。该装置基于电信号传感及PLC控制系统构建，焊接机构采用可拆分设计以适配压力舱

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800 mm舱口尺寸限制，入舱后通过连接板固定保证位置精度，其焊条运动机构具备双自由度倾角调节功能，配合X-Y-Z三轴运动滑块及可调参数的摆动程序模块，可适应不同尺寸试样、焊条规格及坡口焊接需求；控制系统集成电流电压信号传感系统（基于霍尔传感器实现0~10 V信号转换与数据采集）、图像采集系统（含610±5 nm窄带滤光片及不同透过率减光片以获取清晰电弧图像）与西门子S7-200 SMART PLC，能同步采集焊接电信号与电弧图像，并通过逻辑编程实现自动起弧、焊道接续及多位置焊接切换。采用该装置在压力舱0.2 MPa压力环境下开展了典型的立向上多层多道焊接工艺试验，焊缝成形良好，微观组织和力学性能满足要求。试验表明，该自动焊接装置能在压力舱高压环境下替代人工完成高效稳定的焊条自动焊接工艺试验。

Abstract

In order to effectively explore the submerged local dry welding process of SMAW (Submerged Manual Arc Welding) and solve the demand for special equipment for welding tests under high pressure environments

a set of automatic welding devices for electrodes has been developed

which can achieve multi-position welding such as flat

horizontal

vertical

and overhead within a pressure chamber. The device is built on an electrical signal sensing and PLC control system. The welding mechanism adopts a detachable design to fit the

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800 mm hatch size limitation of the pressure chamber. After entering the chamber

it is fixed through the connection plate to ensure position accuracy. Its electrode motion mechanism has a dual-degree of freedom angle adjustment function. Coordinated with the X-Y-Z three-axis motion slider and the adjustable parameter pendulum program module

it can adapt to different sample sizes

electrode specifications

and groove welding requirements. The control system integrates a current and voltage signal sensing system (based on Hall sensors to achieve 0~10 V signal conversion and data collection)

an image acquisition system (with a 610±5 nm narrowband filter and different transmission rate attenuation films to obtain clear arc images)

and Siemens S7-200 SMART PLC

which can synchronously collect welding electrical signals and arc images

and implement automatic arc initiation

bead continuation

and multi-position welding switching through logical programming. Using this device

a typical vertical upward multi-layer and multi-pass welding process test was carried out under the pressure environment of 0.2 MPa in the pressure chamber. The weld formation was good

and the microstructure and mechanical properties met the requirements. The test shows that the automatic welding device can replace manual labor to complete efficient and stable automatic electrode welding process tests under the high-pressure environment of the pressure chamber. It provides key equipment support for exploring the submerged local dry SMAW process under different water depth conditions.

关键词

Keywords

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