Traditional welding technology and equipment and technology can no longer meet the requirements of construction quality and efficiency. In-ground engineering construction, pipeline welding quality, and welding efficiency directly affect the pipeline's life cycle and construction schedule. Generally, the poor working environment on-site and the welder's physical and technical skills instability result in unstable quality. At present, in the general manual GTAW rooting and arc welding fill and cap welding process, the operator has high labor intensity, high skill requirements, low welding efficiency, and slow construction progress.
Some argon arc automatic welding processes have problems such as long preparation time and slow welding speed. In the face of the dense and complex underground pipeline network in the oilfield area, they are basically small and medium-diameter pipelines, and the site conditions for the construction area of the gathering pipeline outside the station are more complicated.
To improve construction efficiency and welding quality, Yixin has specially developed a technical model that combines manual and automatic welding of small and medium-diameter pipelines suitable for oilfield environments. It combines the advantages of human and automatic welding equipment to provide surface engineering for oilfields. Construction adds momentum.
Current technology status:
- Strong welding intensity, low production efficiency, the slow construction process
- Part of the argon arc welding process takes a long time to prepare and slow welding
- Welders have high technical requirements, and high-level welders are difficult to recruit
- The pipelines are dense and complex, and the construction environment is poor
- There are many factors influencing welding, unstable welding performance, and poor welding shape
Development trend:
With the rapid introduction of the welding process method of pipeline all-position automatic welding in the oil and gas pipeline installation industry to solve the problem of welding quality consistency, the industry has gradually deepened the understanding of pipeline all-position automatic welding equipment and process methods. The key problems that can be solved by automatic pipeline welding are becoming clearer. In addition to the good consistency of welding quality, great progress has been made in terms of shortening the training time for welders, reducing labor intensity, and real-time recording of welding process data. The situation in which weld quality depends on the skill level and labor status of the welder from manual welding to the automatic welding process method of all positions of the pipeline increasingly depends on the capacity of the equipment is gradually taking shape. The comprehensive requirement trend of all-position pipeline automatic welding machines is obvious. Now the use of large pipe engineering is very mature. Therefore, the welding of small and medium diameter pipelines is also facing new challenges. The widespread use of automatic welding equipment on small and medium diameter pipelines will also Become an inevitable trend, we should seize the opportunity.
From the perspective of the increasingly mature automatic welding equipment for large pipe diameters, the real automatic welding of pipelines includes: ensuring stable control of the welding process, ensuring effective protection of the arc and molten pool, ensuring the impact toughness of the weld, and ensuring the welding Quality, etc., can not only solve the bottleneck problem that restricts welding flow construction operations but also improves work efficiency.
In the process of large pipe diameter welding, automatic welding technology uses automatic welding technology to complete the welding tasks of on-site nozzles. The stability of its welding quality and welding efficiency has obvious advantages in the flow of construction operations. Automatic welding equipment can be used for pipeline flat welding, vertical welding, horizontal welding, overhead welding, fill welding and cover welding of all-position 5G welding, suitable for welding processes such as GMAW/FCAW-GS. The configuration of different tracks is also suitable for all-position welding requirements of other workpieces. If argon arc root welding is required, manual bottom welding is required. The working principle is that the pipe is fixed, the welding robot is adsorbed on the pipe (or on the track), and automatically crawls and welds. It is operated by wireless remote control. It is protected by carbon dioxide or mixed gas (80% argon + 20% carbon dioxide). The welding wire can be solid. Or flux-cored wire.
Equipment advantages:
1. High degree of intelligence
The original intention of using automatic welding equipment is to liberate manpower and improve welding efficiency. Therefore, the target automatic welding machine has high requirements on the degree of intelligence. The intervention of manpower on the equipment should be reduced as much as possible to liberate manpower and improve efficiency at the same time.
2. High construction convenience
While pursuing intelligent welding, it is also necessary to pay attention to the degree of adaptation at the construction site. The automatic welding equipment should be kept in the most convenient state under the premise of ensuring the basic performance as much as possible to complete the welding task efficiently and be suitable for different projects. Transportation, etc.
3. Good welding effect
Fish-scale welding is considered to be the most advanced welding technology in the world. Because its forming effect is like a fish scale, it is called a fish scale. The weld is beautiful and beautiful, and manual welding is difficult to achieve. It should be used when researching small and medium diameter automatic welding machines. The fish-scale pattern forming is realized as a technical indicator.
Prospects:
At present, my country's welding industry regards the realization of the mechanization and automation of the welding process as a strategic goal. The welding automation industry is an emerging industry and is currently in the development stage. Since the 1990s, with the further maturity of the socialist market economy, my country’s welding industry has made considerable progress. However, welding automation as an emerging industry is still in its infancy. At present, my country still focuses on traditional manual welding. Relevant data shows that the welding automation rate is only about 30%, and the future development potential is huge and the prospects are broad.
The focus of the development of my country's manufacturing industry is to use advanced automation, intelligence, and digital technology to achieve industrial transformation and upgrading and the development of new industries, providing a broad development space for the welding automation industry. With the maturity of digital technology, digital welding machines and digital control technology, which represent automated welding technology, have already appeared and have steadily entered the market. China-Russia oil and gas pipelines, the Three Gorges Project, the West-East Gas Pipeline Project, and shipbuilding projects have promoted the development and progress of advanced welding technology, especially welding automation technology. The welding industry is gradually moving towards "high efficiency, automation, and intelligence".
Post time: May-14-2021