摘要:Spacecraft sealed cabin contains hundreds of resistance spot welding. It’s ultra important to ensure the joint quality through monitoring and controlling the nugget size as well as metallurgy defeats. In order to monitor the spot welding quality of spacecraft sealed cabin,an on-line spot welding monitoring and quality assessment system is developed. Through the statistical analysis of the collected original characteristic information,the eigenvalues of the pressure curve and the dynamic resistance are obtained,and the online assessment of the quality of solder joint spatter,virtual solder joint(or solder joint nugget)is achieved. Verification results show that the system has high credibility. The system has been successfully applied to monitor the welding production of cabin reinforcement ribs. This research might provide some advises to the building of spacecraft digital workshops,and can also improve the ability of quality monitoring and digital traceability during the manufacturing of spacecraft.
摘要:In this paper,design an Internet-based monitoring platform system which is applied to resistance welding machine. The entire system makes full use of the site resistance welding machine networking system that Tianjin 707 Research Institute developed,and aim to supply the remote service of equipment monitoring and data query using internet communication technology. The platform is designed to be a modular and distributed system. The whole system adopts distributed and modular layout,takes the service oriented communication program as the core,designs the communication process among all modules,and provides an efficient and feasible implementation plan for remote monitoring and data query of resistance welding machine.
摘要:"Intelligent manufacturing" is the core of " Made in China 2025",the study of "intelligent welding system of automobile assembly parts" is the exploration and application of "intelligent manufacturing",the first solution is the interconnection of the "intelligent welding of automobile assembly parts". The information layer or virtual layer is deeply integrated with the physical layer and the interaction between the virtual network and the physical world is smooth,Using the existing ERP,MES and APS applications,the intelligent welding interconnection platform is constructed to ensure the normal operation of the intelligent welding system of automobile assembly parts. The "intelligent inference module" embedded in the system can be used to derive the welding parameters and operation instructions required by the production process,real-time monitoring module can monitor the welding process of each device and each welding spot of each car part in real time,ensuring the welding quality of the parts of the automobile assembly.
摘要:This paper presents a USB OTG(On-The-Go)function based on Android system to realize the functions of programming,modifying and saving welding parameters of resistance welding controller. Through related circuit design,the hardware level signal transformation is completed. The software is written in JAVA language,which achieves large data communication,overcomes the interference of strong electromagnetic environment,and preserves the function of big data interface. The system has the advantages of simple structure,convenient connection and high reliability. The software interface is more friendly,the operation is simple,the human-machine interaction has been greatly improved,and user experience has been greatly improved.
摘要:Pneumatic clamp is widely used in automobile welding fixture because of its advantages of convenient operation and low clean cost of power source. Gas path design is an important part of fixture design. The design of gas path system and pipeline layout have certain influence on the structure of welding fixture and the movement track of robot. In this paper,Taking the automobile exhaust system welding fixture as the background,the general steps of the gas circuit design are given,aiming at some problems encountered in the installation and commissioning of gas path components of the solution are put forward,and the corresponding optimization suggestions for gas circuit design are put forward.
摘要:For the reason that the rail flash welding equipment’s distribution scattered in remote locations,equipment management is usually inconvenient especially in case of the equipment failures where the fault is hardly to be handled onsite. Therefore,based on the UN5-150 ZB1 welding machine’s rail flash quality online monitoring and management system,design a remote monitoring management system and remote fault diagnosis system for rail scene flash welding. After comparison of the B/S and the C/S network communication structure,the system adopts the C/S structure for its suitability to the rail scene flash welding. The entire system consists of three subsystems:on-site monitoring computer,central server computer and GPRS network. The on-site monitoring computer is responsible for field data collection and responding to the center server to control the PLC. The center server receives,processes and stores various kinds of information sent from the on-site monitoring computer,besides,it sends related commands and monitors diagnoses to the on-site welding machine. The constructed system can realize the centralized management of multiple rail flash welding machine information in different geographical locations,and make full use of the resources of experts and scholars in remote places to remotely diagnose the faults occurred in the spot welder in time.
关键词:flash butt welding;remote;monitoring and management;fault diagnosis
摘要:It is a difficult issue during large diameter long distance pipeline laying process to implement pipeline welding construction under the condition of steep slope. Traditional welding method is of low construction efficiency;meanwhile defects like porosity,slag inclusion & incomplete fusion are prone to be found. Automatic pipeline welding under the condition of 30° longitudinal grade is achieved through improvements in equipment and process parameters. This article analyzes technical difficult points of automatic welding in mountain area and introduces an equipment and techniques designed for automatic pipeline welding in mountain area.Welding test was taken through which it is showed that the welding equipment and welding method is able to adapt to welding under the condition of 30°longitudinal grade. Welding quality is guaranteed while welding efficiency is raised by a big margin.
关键词:long-distance pipeline;welding on steep slope;automatic welding
摘要:This paper introduces a wave-carrier remote control method used in the intelligent manual welding management system,welders in the welding position of welding parameters and the remote channel current is set,after receiving the welder and PC for data exchange,to confirm whether the production management of the channel and allow the use of current range,if the line allows the welding;if the number of channels set and sent by the welder is different from the number of channels allowed to be issued by the production management center,the channels are determined by the CPU in the welding machine to process the data. The welder interface prompts for an alarm and welding is not allowed. If the channels are the same,after welding machine CPU data processing to determine the same welder at this time to send the welding current value,if the welder to set and send the welding current value is not in the production management issued by the welding current range,after welding machine CPU data processing judgment,welding machine interactive interface alarm,does not allow welding,if the welding current value is within the allowable range,all welding conditions are allowed,and welding is allowed.
LI Juan,LUO Yu,ZHOU Canfeng,HAN Xiaoliang,YANG Chenggong,LU Hao
Vol. 48, Issue 2, Pages: 47-50(2018)
摘要:With the exploitation of the offshore oil and gas,in order to satisfy the increasingly functional demands for the automatic welding equipment of the marine pipeline laying,a human-machine system is designed with the ADS communication as the data exchange mode. Within the system,Twin CAT is the control core,which employs C# language to realize the design and programming of the humanmachine interaction,and exchanges data with Twin CAT system through ADS communication method. The human-machine system enables the task setting and real-time data display of welding process,the independent setting and real-time storage of the welding control parameters and the partition parameters,and the rendering of the dynamic curve to show the change of parameters intuitively. Experiments showed that the human-machine system has the advantages of simple and easy to operate,high real-time ability,and strong data processing ability.
关键词:subsea pipeline welding;human-machine system;C# language;ADS communication method
摘要:In this paper,introduced the equipment and the principle parameters in Ultra-Narrow Gap MAG Welding process applied for 34Cr2Ni2Mo and 35 CrMoV dissimilar steel welding,and then analyzed the microstructures and the mechanical performance via metallographic observation and a series of mechanical measurements of the welded joint. Observed that fine grain microstructures existed in weld bead and HAZ,and a little bigger grain microstructures appeared in a very narrow over-heated zone,the maximum hardness was within the allowable range. In 34Cr2Ni2 Mo side HAZ,a few slag inclusion defects were found. The results of mechanical measurements show the mechanical performance of the welded non-defect founded joint which is much better than base metals. The use of ultra narrow gap MAG welding with low heat input welding technology is conducive to the formation of fine grains in the weld and heat affected zone,through the fine grain strengthening improve the tensile strength of the weld metal greatly,easy to obtain excellent welding joint toughness.
摘要:Aiming at the welding arc stability of aluminum alloy welded by pulse MIG,this paper used the rapid prototype pulse MIG welding power source development platform to control arc length by adjusting pulse duty ratio and pulse frequency. Taking the average arc voltage changes as the feedback signal,the control module of pulse MIG welding power source development platform was designed. The real-time arc control experiment of aluminum alloy was carried out by pulse MIG. The welding tests proved that the control system had good dynamic performance,anti-jamming performance and steady state accuracy. Also,the control system realized the fast and effective control of arc length,obtaining a stable welding process and forming a good weld appearance.
关键词:pulsed MIG;rapid prototyping;arc length control;aluminum alloy;process test
摘要:With the rapid development of welding technology,it is more and more important for the detection of its welding process. As is known to all,besides welding power source,automatic and semi-automatic welding qualities are also affected by the reliability and stability of wire-feeding system directly. The design of speed measurement based Hall speed sensor has realized the real-time display and storage of wire-feeding speed. Analyzed the principle of speed measurement,use the Hall sensor which has the fast response and high measurement precision,combineding with the SCM circuit,a new speed measurement system was designed. Therefore,this study designs a upper computer software based on Lab VIEW. The system has the advantages of low cost,high reliability,fast speed and wide measuring range.
关键词:wire-feeding rate;hall sensor;measurement of rotation rate
摘要:From the perspective of promoting safe production and workers protection,introduce the device of electric welding machine and circuit system and protect the welding operator,which mainly includes the residual current operated protection device,electric welder no-load automatic protection device. The main function of these appliances is to play the role of security protection for electric welding machine and related equipment and operating personnel. The scope of protection is mainly electric welding machine overload;short-circuit electric welding machine and its line;casing and the welding circuit leakage;electric welding machine and line in direct contact with the electric shock and the casing and the welding circuit leakage caused by indirect contact electric shock;secondary noload voltage electric shock.
关键词:electric welding machine;security;electric shock;residual current operated protective devices;electricity divulging
摘要:Due to project requirement,COOEC(Qingdao)qualify a lot of welders every year,and project approval and certificate management are carried out for licensed welders. The workload of welder management is huge. Based on process control,a welder resource management system is developed,which integrates the 8 working processes of welder related to a management platform,one time input will be shared by all work process,thus simplify the process and improve the work efficiency significantly,at the same time,the bar code of the welder certificate and the badge is automatically generated,the bar code can be linked to the database,and the blacklist welder is automatically prompted,which not only realizes the sharing of welding resources and the standardization of information formats,but also provides guarantee for accurate query and tracking welders. The system has been successfully applied to various engineering projects in the company,which has played an important role in reducing the risk of welding quality and improving the utilization of welder’s resources.
摘要:For the transverse cracks during welding of board steel structure in a certain FPSO project,the ultrasonic testing process and its equipment calibration in the process of finding and assessing these cracks are introduced combining with AWS standards. The different characteristics of waveform and amplitude between longitudinal scanning and transverse scanning for transverse cracks are introduced in detail,and the echo characteristic of transverse crack is analyzed,which could be the reference for the construction and quality inspection of other similar steel structure projects.
摘要:Flux-cored wire gas shielded welding is a high quality and efficient welding method,which is widely applied to the pressurebearing welds on the header made of carbon steel,SA-335 P12 and 12 Cr1 Mo VG in boiler industry in the beginning of 21 st century. And the nationalization of these flux-cored wires has been realized. However,for SA-335 P91 material,because the development of flux-cored wire is difficult,the requirements of procedure performance and mechanical property can not be met simultaneously,and R&D cost is high,only a few foreign renowned welding material suppliers research and develop the formula of the flux-cored wire and there are no corresponding welding materials in China now. Therefore,the flux-cored wires for SA-335 P91 made by several famous welding material suppliers are tested,compared and analyzed to study the influence of welding parameters and heat treatment parameters on the properties of SA-335 P91 flux-cored wire joint,thus the influence rules are analyzed and the most reasonable range of welding and heat treatment parameters is obtained. Besides,the macrostructure and microstructure of the welds are observed and analyzed,and further recommendations for improvement are put forward.
WANG Qingtian,LUO Ying,YU Zhiwei,HU Chaowei,ZHANG Yi,LI Yan
Vol. 48, Issue 2, Pages: 82-87(2018)
摘要:The bolt broken fault happened in bottom mounted instrumentation and secondary core support assembly in RVI of Yangjiang NPP Unit 2 is introduced. And the damage caused by this broken fault to primary circuit equipment is also introduced. The reasons of bolts broken fault are analyzed from design,manufacture,installation and operation,and some improvement measures are put forward. These measures can be significant reference for site installation and welding of M310 reactor nuclear power plant and third generation nuclear power plant,such as ACP1000,EPR and AP1000 and so on.
关键词:Yangjiang nuclear power plant;RVI;bolts;broken fault;reason analysis
摘要:Lower rotary platform which is above leg support of circular stockyard stacker is basic unit of rotary to upper stacker and lower stacker. The lower rotary platform is main unit in bearing weight and support weight and dynamic loading of device when circular stockyard stacker is working,so its quality is very strict in welding. In this paper,reasonable welding technology method of quality control for main unit is summed up according to feature of structure of central rotary platform in circular stockyard stacker. Practice has proved that the reasonable welding technology may control effectively deformation of welding and ensure quality of welding,thus laying the foundation for the safe use of the whole machine.
关键词:lower rotary platform;welding technology;quality control
摘要:Aimming at CO2 gas shielded welding flux cored wire pipe butt weld fixed 45 degree appearance and internal quality of weld forming is studied,worked out a complete set of process operating methods. Focuses on the important relationship between the internal quality of weld forming and weld seam forming,each layer of the multilayer weld will directly affect the internal quality of weld,welding operation by controlling welding to improve the qualified rate of weld appearance quality and X ray detection,play a guiding role in the training of teaching and practice.
关键词:appearance of weld;internal quality;welding technology
YANG Lifeng,YU Jingling,CHENG Bo,MA Guangyi,WU Dongjiang
Vol. 48, Issue 2, Pages: 95-99(2018)
摘要:The thin nickel based sheet used in stator and rotor cans of a nuclear main pump is welded by laser and arc. In order to evaluate the effect of different welding technology on the welding quality of cans, the mechanical properties of laser welded joint and argon arc welded joint of can materials are compared and analyzed. Radiographic testing and penetrant testing are used to confirm whether defects exist in welded joints. And tensile experiment and bending experiment of flawless welded joints are carried out. The results show that when ensuring welded joints have good appearance and minimum reinforcement,perfect weld surface can be obtained by both laser welding and arc welding. But radiographic testing shows that the welds obtained by laser welding are evener and the weld with is narrower. The tensile properties of welded joints obtained by laser welding and arc welding are both better than that of base metal. The tensile property of laser welded joints is equivalent to that of arc welded joint. There are no cracks detected in the welded joints after bending experiment.
摘要:Experimental studies are conducted on welding of 08 Ni3 DR steel developed by one steel mill. According to the determined welding technology and parameters,mechanical properties of welded joints of 08 Ni3 DR steels welded by SMAW and SAW respectively,such as tensile,series impact and other properties are systematically studied. The results show that welded joints of 08 Ni3 DR steel have excellent comprehensive mechanical properties,and can meet the design requirements of pressure vessel which applied in temperature not lower than-100 ℃.
摘要:The necessity of the noise reduction on longitudinal critical refraction(LCR)wave for measuring the residual stress of A7 N01 aluminum alloy and S355 J low alloy steel are analyzed. And the calibration processes of A7 N01 and S355 J are respectively realized by the method of stretching, and the local details of noise reduction signal and noise signal are compared,and the calibration result of noise reduction signal and noise signal is finally proposed. Above experimental analysis shows that the influence of stress on the characteristics of ultrasonic transmission in aluminum alloy is more obvious. Noise reduction is very necessary for the stress in S355 J measured by LCR method,while the noise reduction can be ignored for the stress test of A7 N01.
摘要:The solution and aging treatments of MIG weld joint for 6061 aluminum alloy are conducted with the solution temperature of530 ℃ and heat preservation of 4 hours,and aging temperature of 140 ℃,160 ℃,180 ℃ and 200 ℃ respectively and heat preservation of 6 hours. The effect of aging temperature on the microstructure,mechanical properties and fracture mechanism of the welded joint is analyzed. Experimental results show that the postweld solution and aging treatments can effectively improve the softening and mechanical properties of welded joint. The metallographic structure of welds is mainly α(Al)+ β(Mg2 Si),and the distribution is uniform. The distribution of enhance phase β(Mg2Si)is dispersed,which plays a role of dispersion strengthening,and a better comprehensive mechanical property can be obtained when the aging temperature is 180 ℃ with heat preservation of 6 hours.
KANG Ju,WANG Zhichun,WU Yong,ZHAO Weidong,ZENG Yanping,ZHANG Yuanwei
Vol. 48, Issue 2, Pages: 112-117(2018)
摘要:Three kinds of currents are used for welding dissimilar steels with 11% chrome content. And the effect of these welding currents on the microstructures and mechanical properties of welded joints is studied. The tensile, impact and bending properties of the joints are tested. The results show that the microstructures of the joints with three welding technologies are all tempering martensite, and the martensite is much coarser in the 270 A. EDS analysis shows that the secondary phase of welds and heat affected zone is mainly phase M23C6. The joints obtained with 240 A have excellent comprehensive mechanical properties.
摘要:The hinged welding technology of HG785 D thin-walled grooved parts is researched and tested. A reasonable set of welding procedure specification for HG785 D sheet welding is analyzed and summarized. And it can reduce the complex and multiple deformations of thin-walled parts to achieve single-sided welding double-sided forming, and also can effectively solve the technical problems in thin-walled beam welding to ensure the one-time qualified rate of radiographic inspection for welds. And the mechanical property of welds is tested.
摘要:The welding process of common fillet welds along three orthotropic directions in a large-scale metal structure is simulated by finite element method. Five different welding sequences are selected, and the effects of these welding sequences on the residual stress fields of T-joints are simulated and the optimal welding sequence is gained. The results show that the welding sequence affects not only the distribution of temperature field but also the amount and distribution of residual stress. The backstep welding method,which welds middle section first and then welds both ends, can effectively reduce the residual stress of T-joints.
关键词:T-joint;finite element simulation;welding sequence;residual stress
SUN Qiang,QIN Ying,HUANG Jiangzhong,HAO Jianhong,WANG Hongliang,AI Wei
Vol. 48, Issue 2, Pages: 126-129(2018)
摘要:Submerged arc welding(SAW) is a very efficient method widely used in the welding of marine high strength steel. In view of the base metal characteristic and the requirements of construction project,AWS D1.1-2015 "American Welding Society" is taken as the acceptance standard. The four kinds of SAW materials are used in the SAW procedure qualification tests of 32 mm thickness D36 steel plate. The weldability and mechanical properties of welded joints are studied by nondestructive test of appearance,tensile,bending,impact,hardness and macroscopic metallography detection. The results show that welded joints with good mechanical properties can be obtained by using a suitable welding technology with the four kinds of welding materials. And these welding materials can be applied to the SAW of marine high strength steels.
摘要:A new teaching mode has been constructed by introducing the OBE educational idea and CDIO mode into the experiment teaching of welding specialty in Yanshan University, and this mode can cultivate innovative and entrepreneurial talents. In this mode,students can autonomously set goals, and design, operate, analyze and sum up their projects to realize the anticipative learning output.Through the reform of the professional experiments, the ability of students’ creative thinking and entrepreneurial knowledge are improved,which can play a role of leading independent entrepreneurship. A series of welding experiment teaching reforms in Yanshan University make full use of the OBE educational idea and CDIO engineering education mode, and provide a reference for engineering education in China.
关键词:OBE;CDIO;welding experimental teaching;innovation and entrepreneurship;comprehensive experiment
WANG Gang,YAO Zongxiang,ZHANG Liping,CHEN Yuhua,YIN Limeng
Vol. 48, Issue 2, Pages: 135-138(2018)
摘要:"Welding of metal materials" is one of the important courses in welding specialty. Combining with the objective of talents training of welding specialty in application-oriented universities,the course content and teaching mode are redesigned,and a training content about international welding engineer is introduced into the courses. Several teaching methods such as comparison method, on-site teaching method,heuristic method and grouping discussion method are also implemented to emphasize the combination of theory and practice are,and good results are gained.
关键词:"welding of metal materials";teaching reform;comparison method;IWE