Development and Application of Open Automatic Welding Equipment with Molten Pool Monitoring Function

TANG Chunyun; LI Zhuyuan; SUN Qiuyang; TANGHao; YAO Shuyang; LI Gang; ZHANG Xiaodong; SUN Jiacheng; QIAO Wei; HU Xiaoyan; WANG Ying

doi:10.7512/j.issn.1001-2303.2026.02.03

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Development and Application of Open Automatic Welding Equipment with Molten Pool Monitoring Function
Vol. 56, Issue 2, Pages: 30-39(2026)
Received：03 December 2025，

Revised：2026-01-19，

Published：20 February 2026
DOI： 10.7512/j.issn.1001-2303.2026.02.03
稿件说明：

移动端阅览

唐春云，李竹渊，孙秋阳，等.具有熔池监视功能的开放式自动焊接装备研发与应用［J］.电焊机，2026，56（2）：30-39. DOI： 10.7512/j.issn.1001-2303.2026.02.03.

TANG Chunyun, LI Zhuyuan, SUN Qiuyang, et al.Development and Application of Open Automatic Welding Equipment with Molten Pool Monitoring Function[J].Electric Welding Machine, 2026, 56(2): 30-39. DOI： 10.7512/j.issn.1001-2303.2026.02.03.

摘要

为解决核电、石化等管道工程中，传统开放式自动焊装备因缺乏有效熔池可视化手段而导致焊接质量波动大、焊工劳动强度高的难题，研发了一款适用于现场施工、具备熔池实时监视功能的开放式自动焊装备。通过定制国产小型熔池监控相机、优化焊枪结构与焊接机头布局，集成无线传输模块，构建了一体化监控系统。核心技术包括：采用石英玻璃喷嘴与45°折弯式水电气路设计，将熔池观测视线遮挡率从>75%降至<15%；基于5.0 GHz Wi-Fi技术实现端到端传输延迟<80 ms，具备强抗弧光与电磁干扰能力；通过模块化紧凑设计保障装备在狭小空间的适配性。经焊接工艺试验及核电现场规模化应用验证，该装备可实现熔池状态的清晰实时监控，焊缝成形美观且无未熔合、气孔等缺陷，一次合格率≥98%，同时大幅降低了焊工劳动强度。该装备实现了核心部件的国产化替代，打破了国外技术限制，不仅为核电、石化等高端制造业提供了安全高效、自主可控的焊接解决方案，保障了核安全与国家能源安全；更推动我国开放式自动焊装备从“自动化”向“可视化+自动化”跨越式升级，确立了国产高端焊接装备在核心技术领域的竞争优势。

Abstract

To address the challenges of significant welding quality fluctuations and high welder labor intensity in pipeline engineering for nuclear power

petrochemical

and other industries

caused by the lack of effective molten pool visualization methods in traditional open automatic welding equipment

a new type of open automatic welding equipment suitable for on-site construction

equipped with real-time molten pool monitoring function

has been developed. An integrated monitoring system was constructed by customizing domestically produced small molten pool monitoring cameras

optimizing the welding torch structure and welding head layout

and integrating wireless transmission modules. Core technologies include: adopting a quartz glass nozzle and a 45° bent design for water

gas

and electrical lines

reducing the obstruction rate of the molten pool observation line of sight from >75% to <15%; achieving end-to-end transmission delay <80 ms based on 5.0 GHz Wi-Fi technology

with strong resistance to arc light and electromagnetic interference; ensuring equipment adaptability in confined spaces through a modular and compact design. Validated by welding process tests and large-scale on-site applications in the nuclear power industry

this equipment enables clear real-time monitoring of the molten pool status. The resulting welds exhibit good formation without defects such as lack of fusion or porosity

achieving a first-pass yield rate of ≥98%

while significantly reducing the labor intensity for welders. This equipment achieves localization replacement of core components

breaking foreign technological restrictions. It not only provides a safe

efficient

and independently controllable welding solution for high-end manufacturing industries like nuclear power and petrochemicals

safeguarding nuclear safety and national energy security

but also promotes a leapfrog upgrade of China's open automatic welding equipment from "automation" to "visualization + automation

" establishing a competitive advantage for domestic high-end welding equipment in core technological fields.

关键词

Keywords

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