摘要
随着清洁能源需求的快速增长,管道建设用钢管的钢级、管径、壁厚和输送压力逐步提高,管道自动焊技术以其环焊缝强韧性匹配高,焊接效率高、劳动强度低等技术优点,在管道建设中日渐成为主流技术。本文阐述了以管道全位置自动焊技术为载体的长输油气管道焊接机器人技术的发展历程及其在我国工程应用情况,介绍了管道焊接机器人的工程应用特点和技术现状,列举了多焊炬管道焊接机器人、激光—电弧复合管道焊接机器人、双丝管道焊接机器人、搅拌摩擦焊机器人几种先进管道焊接机器人的技术特点和工程应用情况。通过对管道焊接机器人发展存在的问题进行梳理和总结,指出焊接运动轨迹的规划、焊缝跟踪、焊接质量在线监测、特殊工况适应性以及配套焊接电源等是目前油气工程应用存在的技术瓶颈。鉴于对油气管道焊接质量一致性和稳定性提出的高要求,笔者对今后管道焊接机器人智能化研发道路的发展趋势进行了展望,认为3个方向将是未来管道焊接机器人智能化发展趋势:(1)焊接路径的自主规划和自适应焊缝跟踪。对坡口和焊缝信息进行提取、识别和分析,获取理想的路径点和焊枪姿态,并且能够根据工况实时控制焊枪位置,实现管道环焊缝的柔性焊接规划和自适应焊缝跟踪;(2)远程故障诊断。依托大量管道工程应用积累,建立完备的焊接专家系统,对焊接机器人实施远程监控及故障实时诊断,建立网络化的实时监控系统和故障处理系统,实现焊接质量在线监控;(3)人机共融的焊接方式。通过系统深度学习将熟练焊工的经验转化为焊接机器人的训练样本,指导非熟练焊接人员开展焊接培训,人机关系由主仆变为伙伴,共同完成管道焊接作业。
With the rapid growth of demand for clean energy,the steel grade,diameter,wall thickness and transportation pressure of steel pipes for pipeline construction have gradually increased in recent years.The technology of automatic pipeline welding has gradually become the mainstream technology in pipeline construction due to its high matching strength and toughness of girth welds,high welding efficiency and low labor intensity.This paper describes the development process and engineering applications in China of welding robot technology for long-distance oil and gas pipelines.This is based on all-position automatic welding of pipelines,as well as the engineering application characteristics and technical status of pipeline welding robots.Several advanced pipeline welding robots are listed,including a multi-torch pipeline welding robot,laser-arc hybrid pipeline welding robot,double-wire pipeline welding robot and friction stir welding robot.By combining and summarizing the problems existing in the development of pipeline welding robots,it is pointed out that the welding trajectory planning,welding seam tracking,online monitoring of welding quality,the adaptability of special working conditions and supporting welding power supply are the technical bottlenecks in the applications in oil and gas engineering at present.The development of intelligent research and development of pipeline welding robots in the future is examined,and it is believed that three directions will be the development trend of intelligent pipeline welding robots in the future:(1)For the autonomous planning of welding path and adaptive seam tracking technology,the groove and weld information of multi-layer and multi-pass welding of pipeline will be extracted,identified and analyzed to obtain the ideal path point and welding torch posture,and the position of the welding torch can be controlled in real-time according to the working conditions.It will realize flexible welding planning and adaptive seam tracking of pipeline girth welds.(2)For remote fault diagnosis of welding,a complete welding expert system will be established relying on the data accumulation of a large number of pipeline engineering applications,and remote monitoring and real-time fault diagnosis of welding robots will be implemented.Networked real-time monitoring and fault processing systems are established for online monitoring of welding quality;(3)For man-machine integration,the experience of skilled welders will be transformed into training samples for welding robots through deep learning to guide welding training of non-skilled welders.Thus,the man-machine relationship will be changed from master-slave to partnership that will complete pipeline welding work together.
作者
尹铁
赵弘
张倩
吴婷婷
周伦
王新升
YIN Tie;ZHAO Hong;ZHANG Qian;WU Tingting;ZHOU Lun;WANG Xinsheng(College of Mechanical and Transportation Engineering,China University of Petroleum-Beijing,Beijing 102249,China;China Petroleum and Natural Gas Pipeline Research Institute Co.,Ltd.,Langfang 065000,China)
出处
《石油科学通报》
2021年第1期145-157,共13页
Petroleum Science Bulletin
基金
中国石油集团工程股份有限公司科学研究与技术开发项目“第三代管道自动焊关键技术研究”(2017ZYGC-01-01)资助。
关键词
管道焊接机器人
焊接路径
焊缝跟踪
焊接质量在线监测
人机共融
pipeline welding robot
welding path
seam tracking
online monitoring of welding quality
man-machine integration
