阅读说明：本技术 一种高效全自动钢结构焊接技术及其方法 (Efficient full-automatic steel structure welding technology and method thereof ) 是由 孟强海 于 2020-06-04 设计创作，主要内容包括：本发明涉及钢结构焊接技术领域,且公开了高效全自动钢结构焊接的方法,包括以下步骤：焊接方式：考虑焊接成本,焊接技术与现代机械化和自动化生产的条件,焊接方式可选择电阻焊。该高效全自动钢结构焊接技术及其方法,具备实现高效全自动等优点,解决了现有技术中,钢结构焊接大部分采用电阻焊的方式,电阻焊各方面的特点虽然适用与大批量的规模性生产和自动化生产,但电阻焊过程中具有搭接接头焊容易出现产生未熔合与未完全熔合、缩孔、裂纹、结合线伸入、喷溅和压痕过深,对接接头容易出现错位、表面烧伤、未焊透、灰斑、铁素体带、层状撕裂和脆性组织的缺点,对自动化生产造成巨大阻碍的问题。(The invention relates to the technical field of steel structure welding, and discloses a high-efficiency full-automatic steel structure welding method, which comprises the following steps: the welding mode is as follows: considering the welding cost, the welding technology and the conditions of modern mechanization and automation production, the welding mode can be selected from resistance welding. The high-efficiency full-automatic steel structure welding technology and the method thereof have the advantages of realizing high efficiency full automation and the like, and solve the problems that in the prior art, most of steel structure welding adopts a resistance welding mode, the characteristics of all aspects of resistance welding are suitable for large-batch large-scale production and automatic production, but the defects of incomplete fusion, shrinkage cavity, crack, combination line stretching, splashing and indentation are easily caused in lap joint welding, dislocation, surface burn, incomplete penetration, gray spot, ferrite band, layered tearing and brittle tissue are easily caused in butt joint welding, and the automatic production is greatly hindered.)

1. A high-efficiency full-automatic steel structure welding method is characterized by comprising the following steps:

1) the welding mode is as follows: considering the welding cost, the welding technology and the conditions of modern mechanization and automatic production, the welding mode can select resistance welding;

2) process debugging: the lap joint welding is easy to generate incomplete fusion and incomplete fusion, shrinkage cavity, cracks, joint line stretching, splashing and indentation too deep, the butt joint is easy to generate dislocation, surface burn, incomplete welding, gray spot, ferrite band, layered tearing and brittle tissue, and the weld joint is subjected to destructive inspection at each sub-assembly station so as to ensure that the quality of the weld joint meets the process requirement and find a potential suspicious area;

3) the process practice is as follows: repeated pattern and numerical value debugging is carried out on processing numerical values of incomplete fusion, shrinkage cavity, cracks, combination line stretching, splashing and indentation which are easily generated in lap joint welding, dislocation, surface burn, incomplete penetration, gray spots, ferrite bands, layered tearing and brittle tissues which are easily generated in butt joint welding, so that the product quality is improved, the generation of defective products is reduced, and in the pre-production stage, further destructive inspection is carried out on a suspicious area again to ensure that the welding seam quality completely meets the process requirements;

4) in the normal batch production process: the inspection result must be continuously analyzed, and more inspections are continuously performed on the potential suspicious weld joint to ensure that the suspicious weld joint is fully controlled until the adopted corrective measures are really implemented and implemented in the production process;

5) quality inspection: and (4) inspecting and counting the qualification rate of the finished product, wherein the product meets the requirements of an appearance test, a section test and a tensile shear test and is regarded as qualified.

2. A high-efficiency full-automatic steel structure welding technology as claimed in claim 1, wherein said resistance welding has short heating time, heat concentration, small heat affected zone, small deformation and stress, no correction and heat treatment process, no need of filler metal such as welding wire and welding rod, and welding material such as oxygen, acetylene and hydrogen, low welding cost, simple operation, easy mechanization and automation, improved labor condition, high productivity, no noise and harmful gas, and can be assembled with other manufacturing process in mass production.

3. A high-efficiency full-automatic steel structure welding technology as claimed in claim 1, wherein the overlap joint welding is easy to occur and needs to monitor the welding parameters without fusion or incomplete fusion, the shrinkage cavity spot welding can be overcome by using a low inertia electrode and increasing the forging pressure, and can also adopt the standard measures of reducing the cooling speed, the seam welding can only adopt the standard measures of reducing the cooling speed, the crack reduces the cooling speed and pressurizes in time to reduce the internal tensile stress when the small nugget is crystallized, the bonding wire stretches into the surface and needs to clean the residual impurities in time, the melting point is prevented from being increased after accumulation, the indentation is too deep, and the harder welding standard and the strengthening motor need to be adopted for cooling as much as possible, so that the surface temperature of the welded part is reduced.

4. A high-efficiency full-automatic steel structure welding technology as claimed in claim 1, characterized in that the butt joint is easy to misplace and needs the shortest extension length, surface burn can completely remove oxidized impurities through the clamped conductive part of the weldment before welding until metal luster leaks, the clamping force must be large enough, when the alloy steel is welded, the inner side of the water-cooling conductive block is in contact with the weldment and is correspondingly repaired to be smooth transition so as to avoid over steep temperature difference and stress concentration to cause segment lines, only unwelded magnetic powder or fluorescence is used for detecting the parts which are not welded and need to be deburred or machined completely, ultrasonic detection can be used for detecting the internal penetration, the upset allowance needs to be increased for gray spots, oxides on the liquid metal surface are completely extruded, the heating width of the ferrite band needs to be reduced and the upset allowance needs to be increased properly, the laminar tear needs to be formed by adopting a forced forming upset process, the stress state of the joint is changed, and proper welding parameters are selected to ensure that liquid metal is completely extruded under the condition of the minimum upset allowance, the brittle tissue needs to be subjected to post-heat treatment, and measures must be taken on the material with high crack tendency from the aspect of process to prevent the material from being cooled too fast.

5. The efficient and full-automatic steel structure welding technology according to claim 1, wherein the repeated debugging in the process debugging stage can effectively ensure the reduction of the error amount of the process practice, and parameters are continuously updated and improved according to the defects of actual parameters in the process practice process, so that the quality is improved.

6. The efficient and full-automatic steel structure welding technology according to claim 1, wherein the product meets the requirements of an appearance test, a section test and a tensile shear test, and a targeted detection step can be added for welding of steel structures with other special requirements.

Technical Field

The invention relates to the technical field of steel structure welding, in particular to a high-efficiency full-automatic steel structure welding technology and a method thereof.

Background

The steel structure welding manufacture (i.e. welding structure production) is started from the preparation work of welding production, and comprises the steps of technological examination of the structure, design of technological scheme and technological procedures, technological evaluation, establishment of technological documents (including rated establishment) and quality assurance documents, ordering of raw materials and auxiliary materials, outsourcing and self-design manufacture assembly-welding equipment and equipment, and then the whole process of welding structure manufacturing process is really started from material warehousing, and comprises material re-inspection warehousing, material preparation processing, assembly-welding, post-welding heat treatment, quality inspection and finished product acceptance, wherein repair, coating and painting are alternated, and finally, the whole process of qualified product warehousing is completed.

Disclosure of Invention

Technical problem to be solved

Aiming at the defects of the prior art, the invention provides an efficient full-automatic steel structure welding technology and a method thereof, which have the advantages of realizing high efficiency full automation and the like, and solve the problems that in the prior art, most steel structure welding adopts a resistance welding mode, and although the characteristics of all aspects of resistance welding are suitable for large-scale production and automatic production, the resistance welding process has the defects that the lap joint welding easily generates incomplete fusion and incomplete fusion, shrinkage cavities, cracks, combination line stretching, splashing and too deep indentation, and the butt joint easily generates dislocation, surface burning, incomplete welding, gray spots, ferrite bands, layered tearing and brittle tissues, thereby causing huge obstruction to the automatic production.

(II) technical scheme

In order to realize the purpose of realizing high efficiency and full automation, the invention provides the following technical scheme:

the invention aims to solve another technical problem of providing a high-efficiency full-automatic steel structure welding method, which comprises the following steps:

1) the welding mode is as follows: considering the welding cost, the welding technology and the conditions of modern mechanization and automatic production, the welding mode can select resistance welding;

2) process debugging: the lap joint welding is easy to generate incomplete fusion and incomplete fusion, shrinkage cavity, cracks, joint line stretching, splashing and indentation too deep, the butt joint is easy to generate dislocation, surface burn, incomplete welding, gray spot, ferrite band, layered tearing and brittle tissue, and the weld joint is subjected to destructive inspection at each sub-assembly station so as to ensure that the quality of the weld joint meets the process requirement and find a potential suspicious area;

3) the process practice is as follows: repeated pattern and numerical value debugging is carried out on processing numerical values of incomplete fusion, shrinkage cavity, cracks, combination line stretching, splashing and indentation which are easily generated in lap joint welding, dislocation, surface burn, incomplete penetration, gray spots, ferrite bands, layered tearing and brittle tissues which are easily generated in butt joint welding, so that the product quality is improved, the generation of defective products is reduced, and in the pre-production stage, further destructive inspection is carried out on a suspicious area again to ensure that the welding seam quality completely meets the process requirements;

4) in the normal batch production process: the inspection result must be continuously analyzed, and more inspections are continuously performed on the potential suspicious weld joint to ensure that the suspicious weld joint is fully controlled until the adopted corrective measures are really implemented and implemented in the production process;

5) quality inspection: and (4) inspecting and counting the qualification rate of the finished product, wherein the product meets the requirements of an appearance test, a section test and a tensile shear test and is regarded as qualified.

Preferably, the resistance welding has short heating time, heat concentration, small heat affected zone, small deformation and stress, no need of arranging correction and heat treatment process after welding, no need of filling metal such as welding wire and welding rod, and welding material such as oxygen, acetylene and hydrogen, low welding cost, simple operation, easy realization of mechanization and automation, improved labor condition, high productivity, no noise and harmful gas, and can be combined with other manufacturing process on an assembly line in mass production.

Preferably, lap joint welds the control that the production appears not fusing with not fusing completely needs to strengthen the welding parameter easily, available low inertia electrode and increase forging pressure overcome during the shrinkage cavity spot welding, also can adopt the standard measure who slows down cooling rate, only can adopt the standard measure who slows down cooling rate during the seam welding, the crack slows down cooling rate and in time pressurizes, inside tensile stress when reducing little nugget crystallization, the joint line stretches into and needs to carry out timely clearance to the remaining impurity on surface, avoid piling up the back and improve the melting point, the indentation is too deep and needs to adopt harder welding standard and strengthen the motor cooling as far as, reduce welding piece surface temperature.

Preferably, the butt joint is easy to have dislocation and needs the shortest extension length, surface burn can thoroughly remove oxidized impurities through a clamping conductive part of a corresponding weldment before welding until metal luster leaks, the clamping force is enough, when the alloy steel is welded, the inner side of a water-cooling conductive block is in contact with the weldment and is correspondingly repaired into smooth transition so as to avoid section lines caused by over steep temperature difference and stress concentration, in parts which are not welded completely and need to be deburred or machined, only parts which are not welded and extend to the surface are detected by using magnetic powder or fluorescence and the like, the inner parts can be detected by ultrasonic waves for penetration, gray spots need to be enlarged in upsetting amount, oxides on the surface of liquid metal are thoroughly extruded, a ferrite band needs to be reduced in heating width and properly enlarged in upsetting amount, a forced forming upsetting process is needed for laminar tearing, the stress state at the joint is changed, appropriate welding parameters are selected so as to ensure that the liquid metal is completely extruded under the minimum upsetting amount, the brittle tissue needs post heat treatment, and materials with high crack tendency must be technically taken to prevent too fast cooling.

Preferably, the repeated debugging in the process debugging stage can effectively ensure the reduction of the error amount in the process practice, and parameters are continuously updated and improved according to the defects of actual parameters in the process practice process, so that the quality is improved by corresponding adjustment.

Preferably, the product meets the requirements of an appearance test, a section test and a tensile shear test, and a targeted detection step can be added for part of steel structure welding with other special requirements:

(III) advantageous effects

Compared with the prior art, the invention provides an efficient full-automatic steel structure welding technology and a method thereof, and the efficient full-automatic steel structure welding technology has the following beneficial effects:

1. the high-efficiency full-automatic steel structure welding technology and the method thereof can easily generate unfused and incomplete fusion through lap joint welding, can overcome by using a low inertia electrode and increasing forging pressure during shrinkage hole spot welding, can also adopt a standard measure for reducing cooling speed, can only adopt the standard measure for reducing cooling speed during seam welding, can reduce cooling speed of cracks and pressurize in time so as to reduce internal tensile stress during crystallization of small nuggets, can timely clean residual impurities on the surface by stretching a bonding wire, can avoid improving melting point after stacking, can reduce the surface temperature of a welding part by adopting harder welding standard and strengthening motor cooling as far as possible due to too deep indentation, can easily generate dislocation at a butt joint, can need the shortest stretching length, can thoroughly remove oxidized impurities on a clamping conductive part of the welding part before welding surface burn until metal luster leaks, the clamping force must be large enough, when the alloy steel is welded, the inner side of the water-cooling conducting block is in contact with a weldment and is correspondingly trimmed into smooth transition so as to avoid section lines caused by too steep temperature difference and stress concentration, the unsoldered part needs to be detected by methods of magnetic powder or fluorescence and the like only when the part is not welded on the surface, the inside part can be detected by ultrasonic waves for thorough welding, the spot on the surface of the part needs to be enlarged and upset allowance is increased for thoroughly extruding oxides on the surface of the liquid metal, the ferrite strip needs to reduce the heating width and properly increase the upset allowance, the laminar tearing needs to adopt a forced forming upset process, the stress state of a joint is changed, proper welding parameters are selected so as to ensure that the liquid metal is completely extruded under the minimum upset allowance, the brittle tissue needs to be subjected to post-heat treatment, measures must be taken from the process for the material with large crack tendency, the cooling is prevented from being too fast, and most problems of resistance welding in the automatic welding of the steel structure can be solved, the defects that the lap joint welding is easy to generate incomplete fusion, shrinkage cavity, crack, combination line stretching, splashing and indentation too deep, and the butt joint is easy to generate dislocation, surface burn, incomplete penetration, gray spot, ferrite band, layered tearing and brittle tissue are overcome, and the aim of realizing high efficiency and full automation is achieved.

2. The high-efficiency full-automatic steel structure welding technology and the method thereof have the advantages that the heating time is short through resistance welding, the heat is concentrated, the heat affected zone is small, the deformation and the stress are small, the correction and heat treatment processes are not required to be arranged after welding generally, welding wires, welding rods and other filling metals are not required, and oxygen, acetylene, hydrogen and other welding materials are not required.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

1. A high-efficiency full-automatic steel structure welding method comprises the following steps:

1) the welding mode is as follows: considering the welding cost, the welding technology and the conditions of modern mechanization and automation production, the welding mode can select resistance welding, the heating time of the resistance welding is short, the heat is concentrated, the heat affected zone is small, the deformation and the stress are small, generally, the correction and heat treatment processes are not needed to be arranged after the welding, the filling metals such as welding wires and welding rods, and the welding materials such as oxygen, acetylene, hydrogen are not needed, the welding cost is low, the operation is simple, the mechanization and automation are easy to realize, the labor condition is improved, the production efficiency is high, and no noise and harmful gas exist, and the welding method can be compiled on an assembly line together with other manufacturing processes in the mass production;

2) process debugging: the lap joint welding is easy to generate unfused and incomplete fusion, shrinkage cavity, crack, joint line stretching, splashing and indentation are too deep, the butt joint is easy to generate dislocation, surface burn, incomplete fusion, gray spot, ferrite band, layered tearing and brittle tissue, destructive inspection is carried out on the welding line at each sub-assembly station to ensure that the welding line quality meets the process requirement and find a potential suspicious area, the lap joint welding is easy to generate unfused and incomplete fusion and needs to strengthen the monitoring of welding parameters, the shrinkage cavity spot welding can be overcome by a low inertia electrode and increase of forging pressure, and a standard measure for reducing the cooling speed can be adopted, only the standard measure for reducing the cooling speed can be adopted during seam welding, the crack reduces the cooling speed and pressurizes in time to reduce the internal tensile stress during small-nugget crystallization, and the joint line stretching needs to clean the residual impurities on the surface in time, the melting point is prevented from being improved after the accumulation, the indentation needs to be cooled by adopting harder welding specifications and a strengthening motor as far as possible, the surface temperature of a welding part is reduced, the butt joint is easy to have dislocation and needs the shortest extension length, surface burn can thoroughly remove oxidation impurities through a clamping conductive part corresponding to the welding part before welding until metal luster leaks, the clamping force needs to be large enough, when alloy steel is welded, the inner side of a water-cooling conductive block is in contact with the welding part and is correspondingly repaired into smooth transition so as to avoid the condition that the temperature difference is too steep and stress concentration causes section lines, the parts which are not welded completely need to be deburred or machined, only the parts which are not welded and extend to the surface are detected by using methods such as magnetic powder or fluorescence, the inside can be detected by ultrasonic waves for complete welding, the upset forging allowance needs to be increased for gray spots, oxides on a liquid metal surface are thoroughly extruded, the heating width and the upset forging allowance needs to be, the method is characterized in that a forced forming upsetting process is adopted for laminar tearing, the stress state of a joint is changed, and proper welding parameters are selected to ensure that liquid metal is completely extruded under the minimum upsetting allowance, a brittle tissue needs to be subjected to post-heat treatment, and measures must be taken on the process for a material with a large crack tendency to prevent the material from being cooled too fast;

3) the process practice is as follows: repeated pattern and value debugging is carried out on processing values of incomplete fusion, shrinkage cavity, cracks, combination line stretching, splashing and indentation depth easily caused by lap joint welding and dislocation, surface burn, incomplete welding, gray spots, ferrite band, layered tearing and brittle tissue easily caused by butt joint welding, so that the product quality is improved, the generation of defective products is reduced, further destructive inspection is carried out on a suspicious area in the pre-production stage, the welding seam quality is ensured to completely meet the process requirements, the reduction of process practice error can be effectively ensured through repeated debugging in the process debugging stage, and parameters are continuously updated and improved according to actual parameter defects in the process of process practice, and corresponding adjustment is carried out to improve the quality;

4) in the normal batch production process: the inspection result must be continuously analyzed, and more inspections are continuously performed on the potential suspicious weld joint to ensure that the suspicious weld joint is fully controlled until the adopted corrective measures are really implemented and implemented in the production process;

5) quality inspection: the qualification rate of the finished product is checked and counted, the product meets the requirements of an appearance test, a section test and a tensile shear test and is regarded as qualified, the product meets the requirements of the appearance test, the section test and the tensile shear test and is regarded as qualified, and a targeted detection step can be added for welding of steel structures with other special requirements.

The invention has the beneficial effects that: the monitoring of welding parameters which need to be strengthened when incomplete fusion and incomplete fusion occur easily through lap joint welding, the defect of low inertia electrode and increased forging pressure can be overcome during shrinkage hole spot welding, and a standard measure for reducing cooling speed can also be adopted, only the standard measure for reducing cooling speed can be adopted during seam welding, cracks can reduce cooling speed and pressurize in time so as to reduce internal tensile stress when small nuggets are crystallized, a bonding wire stretches into residual impurities on the surface to be cleaned in time, the melting point is prevented from being improved after accumulation, harder welding standards and strengthened motors are adopted to cool as far as possible when indentations are too deep, the surface temperature of a welding part is reduced, the shortest stretching length is required when the butt joint is easy to be dislocated, surface burn can thoroughly remove oxidized impurities on the clamping conductive part of the welding part before welding until metal luster is leaked, the clamping force must be large enough, and when the alloy steel is welded, the inner side of the water-cooling conducting block is in contact with the weldment and is correspondingly repaired into smooth transition so as to prevent section lines caused by too steep temperature difference and stress concentration from being welded completely in the part which is deburred or machined, only the unwelded magnetic powder or fluorescence which is expanded to the surface is detected, the inside can be detected by ultrasonic waves for penetration, the upset forging allowance needs to be increased for gray spots, oxides on the liquid metal surface are thoroughly extruded, the heating width of the ferrite band needs to be reduced, the upset forging allowance needs to be properly increased, the forced forming upset forging process needs to be adopted for laminar tearing, the stress state of a joint is changed, proper welding parameters are selected, so as to ensure that the liquid metal is completely extruded under the minimum upsetting allowance, the brittle structure needs to be subjected to post-heat treatment, the material with large crack tendency must be technically taken measures to prevent the material from being cooled too fast, and most problems of the resistance welding during the automatic welding of the steel structure can be solved.

Moreover, the electric resistance welding has short heating time and concentrated heat, so the heat affected zone is small, the deformation and the stress are small, the correction and the heat treatment processes are not needed to be arranged after the welding, the filling metals such as welding wires and welding rods and the welding materials such as oxygen, acetylene, hydrogen and the like are not needed, the welding cost is low, the operation is simple, the mechanization and the automation are easy to realize, the labor condition is improved, the productivity is high, the noise and the harmful gas are not generated, the electric resistance welding can be combined with other manufacturing processes on an assembly line in the mass production, the automatic welding robot in the prior art can effectively replace the manual welding, the production efficiency is improved, the labor cost is reduced, and the problems that the lap joint welding easily generates unfused and incompletely fused parts, shrinkage holes, cracks, the joint line stretches into, splashes and indentations are too deep, and the butt joint is easy to generate dislocation, Surface burn, incomplete welding, gray spots, ferrite bands, layer tearing and fragile tissues, and the aim of realizing high efficiency and full automation is fulfilled.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.