大型抽水蓄能球阀机器人窄间隙焊接工艺研究与应用

郭中才; 冯涛; 钟磊; 金宝; 范潇

doi:10.7512/j.issn.1001-2303.2022.09.09

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大型抽水蓄能球阀机器人窄间隙焊接工艺研究与应用
Research and Application of Narrow Gap Robot Welding Technology of Large Pumped Storage Unit Ball Valve
2022年52卷第9期页码：60-65
DOI： 10.7512/j.issn.1001-2303.2022.09.09

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郭中才，冯涛，钟磊，等.大型抽水蓄能球阀机器人窄间隙焊接工艺研究与应用［J］.电焊机，2022，52（9）：60-65.

GUO Zhongcai, FENG Tao, ZHONG Lei, et al.Research and Application of Narrow Gap Robot Welding Technology of Large Pumped Storage Unit Ball Valve[J].Electric Welding Machine, 2022, 52(9): 60-65.
郭中才，冯涛，钟磊，等.大型抽水蓄能球阀机器人窄间隙焊接工艺研究与应用［J］.电焊机，2022，52（9）：60-65. DOI： 10.7512/j.issn.1001-2303.2022.09.09.

GUO Zhongcai, FENG Tao, ZHONG Lei, et al.Research and Application of Narrow Gap Robot Welding Technology of Large Pumped Storage Unit Ball Valve[J].Electric Welding Machine, 2022, 52(9): 60-65. DOI： 10.7512/j.issn.1001-2303.2022.09.09.

摘要

为解决采用传统焊接工艺制造大型抽水蓄能球阀部件存在的工作量大、劳动强度高、资源消耗大的问题，通过将窄间隙GMAW焊接技术与机器人焊接技术有机结合，对球阀阀体焊接工艺结构设计、机器人窄间隙横焊工艺、球阀阀体焊接变形控制、焊接质量过程控制等关键技术进行了研究。设计了一种适用于机器人焊接的球阀阀体窄间隙焊接坡口，并通过小试样试验对摆动电弧式窄间隙GMAW焊接的各关键参数进行分析与论证，确定工艺参数范围，并结合抽水蓄能机组球阀阀体焊接制造过程，设置合理的反变形量，制定焊接质量控制措施，开发了一种适用于大型球阀阀体的机器人窄间隙横向焊接的新制造工艺，在某抽水蓄能产品球阀上进行应用，产品焊缝经过UT及TOFD探伤检测，探伤合格率99%以上。结果表明该工艺技术可行，实现了产品质量稳定高效的焊接，降低了工人劳动强度，达到了节能减排的效果。

Abstract

In order to solve the problem of heavy workload, high labor intensity and resource consumption caused by traditional welding process manufacturing for the ball valve of the large pumped storage unit, by combining narrow gap GMAW technology with robot welding technology, the key technologies are studied, including welding process structure design and deformation control of ball valve body, robot narrow gap transverse welding process, welding quality process control. The narrow gap welding groove of ball valve body suitable for robot welding is designed, and through small sample test, the key parameters of swing arc narrow gap GMAW are analyzed and proved, and welding parameters ranges are determined. Combining with the welding and manufacturing of ball valve body of pumped storage group, the reasonable reverse deformation is set, the welding quality control measures are laid down, and a new manufacturing technology of robot narrow gap transverse welding for large ball valve body is developed. This new technology has been applied to a ball valve of a pumped storage product. The welds of this product are tested by UT and TOFD flaw detection, and the pass rate is over 99%. The results show that this technology is feasible, which realizes the stable and efficient welding, reduces the labor intensity of workers, and achieves the effect of energy saving and emission reduction.

关键词

球阀制造机器人焊接窄间隙焊接质量焊接变形

Keywords

ball value manufacturingrobot weldingnarrow gapwelding qualitywelding deformation

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