CN104846174B - A kind of cylindrical leg weld residual stress cancellation element and method - Google Patents
A kind of cylindrical leg weld residual stress cancellation element and method Download PDFInfo
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Abstract
本发明提供一种圆柱形桩腿焊缝残余应力消除装置及方法，该装置包括底板、变频器、电机、摩擦轮及冲击头，所述电机和所述变频器设置在底板上，所述电机为对称设置，所述摩擦轮位于所述电机上，所述圆柱形桩腿位于所述摩擦轮上方，所述冲击头对称设置在所述圆柱形桩腿的内壁或外壁，与所述圆柱形桩腿的焊缝表面夹角为90度，冲击点位于所述焊缝两侧。整个装置结构简单，适用范围广，所述消除方法操作方便，减轻了工人的劳动强度，大大增加了工作效率，有利于实现自动化作业。
The invention provides a device and method for eliminating residual stress of a cylindrical leg weld. The device includes a bottom plate, a frequency converter, a motor, a friction wheel and an impact head. For symmetrical arrangement, the friction wheel is located on the motor, the cylindrical leg is located above the friction wheel, the impact head is symmetrically arranged on the inner or outer wall of the cylindrical leg, and the cylindrical leg The included angle of the weld seam surface of the pile leg is 90 degrees, and the impact point is located on both sides of the weld seam. The whole device has simple structure and wide application range, and the elimination method is easy to operate, reduces labor intensity of workers, greatly increases work efficiency, and is beneficial to realize automatic operation.
Description
技术领域technical field
本发明涉及海洋工程装备的制造技术领域，尤其涉及一种海上风电安装船圆柱形桩腿的焊接残余应力消除装置及方法。The invention relates to the technical field of manufacturing marine engineering equipment, in particular to a welding residual stress relief device and method for cylindrical legs of an offshore wind power installation ship.
背景技术Background technique
随着能源紧缺状况的加剧和风电场土地资源的日益紧张，海上风能发电也成为当今世界风能发电的发展新方向。海上风电机组的安装相对于陆上风电机组的安装具有更高的技术难度，需要专门的风电安装船承担运输和安装才能完成。当风电安装船在海上作业时，桩腿下降插入海底，并将风电安装船提升并离开海面一定高度，形成作业平台。因此，桩腿是风电安装船的关键部件，承担着整个风电安装平台的安全，并决定了风电机组的安装精度。With the aggravation of energy shortage and the increasing shortage of wind farm land resources, offshore wind power generation has become a new direction for the development of wind power generation in the world today. Compared with the installation of onshore wind turbines, the installation of offshore wind turbines is more technically difficult, and requires a special wind power installation ship to undertake the transportation and installation to complete. When the wind power installation ship is operating at sea, the pile legs are lowered and inserted into the seabed, and the wind power installation ship is lifted to a certain height above the sea surface to form an operation platform. Therefore, the pile legs are the key components of the wind power installation ship, responsible for the safety of the entire wind power installation platform, and determine the installation accuracy of the wind power unit.
风电安装船用的圆柱形桩腿圆柱形壳体直径一般为2m～5m，板厚一般为100mm～200mm，高度一般为50m～70米，属于超大型超重精密设备零件。圆柱形桩腿的制造通常采用分段焊接的方式，由于圆柱形桩腿在整体强度和尺寸精度上均有较高的要求，因此，必须对焊接变形进行有效控制，否侧会对桩腿的尺寸和外形产生影响。而焊接应力是导致桩腿整体变形的主要原因，另一方面，焊接应力还会导致焊缝处的疲劳性能远低于基体金属。可见，如何降低或者调节残余应力场，对于提高桩腿整体强度和尺寸精度具有重要意义。The diameter of the cylindrical pile legs used for wind power installation ships is generally 2m to 5m, the thickness of the plate is generally 100mm to 200mm, and the height is generally 50m to 70m, which belongs to super large and heavy precision equipment parts. Cylindrical legs are usually manufactured by segmented welding. Since cylindrical legs have high requirements on overall strength and dimensional accuracy, the welding deformation must be effectively controlled, otherwise the side will affect the leg. Size and shape matter. The welding stress is the main cause of the overall deformation of the pile leg. On the other hand, the welding stress will also cause the fatigue performance of the weld to be much lower than that of the base metal. It can be seen that how to reduce or adjust the residual stress field is of great significance for improving the overall strength and dimensional accuracy of pile legs.
超声冲击处理是消除焊接残余应力、提高焊接结构抗疲劳性能的主要措施。中国兵器工业第五二研究所公开了一种用于焊缝应力消除的高效超声冲击头(专利号：ZL200810162683.5)，采用对称的两枚冲击针同时处理焊缝两边的焊趾，显著提高了冲击效率，但是该发明没有涉及到对超大型圆柱形桩腿焊接残余应力的消除。Ultrasonic impact treatment is the main measure to eliminate welding residual stress and improve fatigue resistance of welded structures. The 52nd Research Institute of China Ordnance Industry has disclosed a high-efficiency ultrasonic impact head for weld stress relief (patent number: ZL200810162683.5), which uses two symmetrical impact needles to simultaneously treat the weld toes on both sides of the weld, significantly improving The impact efficiency is improved, but this invention does not relate to the elimination of the welding residual stress of the ultra-large cylindrical pile leg.
发明内容Contents of the invention
为克服现有技术中存在的圆柱形桩腿残余应力消除过程中引起桩腿变形及消除方法不便于操作、适用范围小的问题，本发明提供一种针对风电安装船圆柱形桩腿焊缝残余应力消除装置及方法。In order to overcome the problems in the prior art that the deformation of the cylindrical legs caused by the residual stress elimination process of the cylindrical legs and the elimination method are not easy to operate and the application range is small, the present invention provides a method for the residual stress of the cylindrical legs of the wind power installation ship. Stress relief apparatus and method.
一种圆柱形桩腿焊缝残余应力消除装置，其特征在于：包括底板、变频器、电机、摩擦轮及冲击头，所述电机和所述变频器设置在所述底板上，所述电机为对称设置，所述摩擦轮位于所述电机上，所述圆柱形桩腿位于所述摩擦轮上方，所述冲击头对称设置在所述圆柱形桩腿的内壁或外壁，与所述圆柱形桩腿的焊缝表面夹角为90度，所述冲击头与所述圆柱形桩腿的内壁或外壁接触的位置为冲击点，所述冲击点位于所述焊缝两侧。A cylindrical leg weld residual stress relief device is characterized in that it includes a base plate, a frequency converter, a motor, a friction wheel and an impact head, the motor and the frequency converter are arranged on the base plate, and the motor is Symmetrically arranged, the friction wheel is located on the motor, the cylindrical leg is located above the friction wheel, the impact head is symmetrically arranged on the inner wall or outer wall of the cylindrical leg, and the cylindrical pile The angle between the weld surface of the leg is 90 degrees, and the position where the impact head contacts the inner or outer wall of the cylindrical leg is the impact point, and the impact point is located on both sides of the weld.
所述圆柱形桩腿外径范围为2m～10m。The outer diameter of the cylindrical pile leg ranges from 2m to 10m.
所述变频器驱动所述电机；所述电机采用变频调速，驱动所述的摩擦轮旋转，所述摩擦轮的线速度在0.5m/min～1.5m/min之间连续可调。The frequency converter drives the motor; the motor adopts frequency conversion speed regulation to drive the friction wheel to rotate, and the linear speed of the friction wheel is continuously adjustable between 0.5m/min˜1.5m/min.
所述冲击头为超声冲击头。The impact head is an ultrasonic impact head.
所述摩擦轮为4个，所述冲击头为2个。There are four friction wheels, and two impact heads.
一种圆柱形桩腿焊缝残余应力消除方法，包括以下几个步骤：A method for eliminating residual stress of a cylindrical pile leg weld, comprising the following steps:
步骤一、将待焊接的圆柱形桩腿平卧放置于摩擦轮上；Step 1. Place the cylindrical leg to be welded flat on the friction wheel;
步骤二、启动变频器，驱动电机运行，带动所述摩擦轮旋转，使所述圆柱形桩腿在所述摩擦轮上平稳的等速均匀旋转；Step 2, start the frequency converter, drive the motor to run, and drive the friction wheel to rotate, so that the cylindrical leg rotates smoothly and uniformly at the same speed on the friction wheel;
步骤三、调节变频器，使所述圆柱形桩腿的外圆面的线速度在0.5m/min～1.5m/min之间；Step 3. Adjust the frequency converter so that the linear velocity of the outer surface of the cylindrical leg is between 0.5m/min and 1.5m/min;
步骤四、将冲击头对称设置在所述圆柱形桩腿内壁，调整所述冲击头与所述圆柱形桩腿的焊缝表面距离为2mm，并呈90度夹角；Step 4, symmetrically arrange the impact head on the inner wall of the cylindrical leg, adjust the distance between the impact head and the weld surface of the cylindrical leg to be 2mm, and form an included angle of 90 degrees;
步骤五、启动所述冲击头，在所述圆柱形桩腿转动时连续对称地冲击焊趾，待所述圆柱形桩腿转动一周时，停止冲击和旋转；Step 5, start the impact head, continuously and symmetrically impact the welding toe when the cylindrical leg rotates, and stop the impact and rotation when the cylindrical leg rotates once;
步骤六、将所述冲击头对称设置在所述圆柱形桩腿外壁，调整所述冲击头与所述圆柱形桩腿的焊缝表面距离为2mm，并呈90度夹角；Step 6, symmetrically arrange the impact head on the outer wall of the cylindrical leg, adjust the distance between the impact head and the weld surface of the cylindrical leg to be 2 mm, and form an included angle of 90 degrees;
步骤七、再次启动所述冲击头，在所述圆柱形桩腿转动时连续对称地冲击所述焊趾，待所述圆柱形桩腿转动一周时，停止冲击和旋转，完成残余应力消除操作。Step 7: start the impact head again, continuously and symmetrically impact the welding toe when the cylindrical leg rotates, and stop the impact and rotation when the cylindrical leg rotates one circle, and complete the residual stress relief operation.
所述步骤一包括：所述圆柱形桩腿外径范围为2m～10m。The first step includes: the outer diameter of the cylindrical leg is in the range of 2m to 10m.
所述步骤二包括：所述电机采用变频调速，对称设置，所述摩擦轮为4个。The second step includes: the motor adopts frequency conversion speed regulation, symmetrically arranged, and there are four friction wheels.
所述步骤四包括：所述冲击头为超声冲击头，数量为2个。The fourth step includes: the impact head is an ultrasonic impact head, and the number is two.
与现有技术相比，本发明的有益效果是：本发明提供了一种圆柱形桩腿焊缝残余应力消除装置及方法，整个装置结构简单，将冲击头对称布置，有利于保持桩腿内应力的平衡，避免在去除残余应力过程中引起桩腿的变形。由于风电安装船圆柱形桩腿直径一般在2m以上，故本发明的圆柱形桩腿残余应力消除方法十分便于操作，易于减轻工人的劳动强度，实现自动化作业。此外，本发明采用连续旋转的方式，可以快速且准确的对圆柱形桩腿焊缝的残余应力进行去除，大大增加了工作效率。Compared with the prior art, the beneficial effect of the present invention is that the present invention provides a device and method for eliminating the residual stress of the cylindrical leg weld. Stress balance to avoid deformation of pile legs during the process of removing residual stress. Since the diameter of the cylindrical pile leg of the wind power installation ship is generally more than 2m, the method for eliminating the residual stress of the cylindrical pile leg of the present invention is very easy to operate, easy to reduce the labor intensity of workers, and realize automatic operation. In addition, the present invention adopts the mode of continuous rotation, which can quickly and accurately remove the residual stress of the welding seam of the cylindrical leg, thereby greatly increasing the work efficiency.
附图说明Description of drawings
图1是圆柱形桩腿焊缝残余应力的消除装置示意图；Fig. 1 is a schematic diagram of a device for eliminating residual stress of a cylindrical leg weld;
图2是图1中冲击点(虚线部分)的局部放大图。Fig. 2 is a partially enlarged view of the impact point (dotted line part) in Fig. 1 .
图中标号：1-桩腿、2-冲击头、3-摩擦轮、4-电机、5-变频器、6-底板。Labels in the figure: 1-leg, 2-impact head, 3-friction wheel, 4-motor, 5-frequency converter, 6-bottom plate.
具体实施方式detailed description
以下结合附图和实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明。The present invention will be described in further detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.
一种圆柱形桩腿焊缝残余应力消除装置，如图1所示，包括底板6、变频器5、电机3、摩擦轮4以及冲击头2，电机对称设置在底板上，变频器也设置在底板上，摩擦轮位于电机上，圆柱形桩腿1卧放于摩擦轮4的上方，两个冲击头2对称设置在桩腿1的内壁或者外壁，这样有利于保持桩腿内应力的平衡，避免在去除残余应力过程中引起桩腿的变形。如图2所示，该冲击头2与圆柱形桩腿1的焊缝表面夹角为90度，冲击头2与圆柱形桩腿1的内壁或外壁接触的位置为冲击点，冲击点位于焊缝两侧。本发明的装置中摩擦轮4为四个，分为两组，电机3采用变频调速，驱动摩擦轮4旋转，使摩擦轮4的线速度在0.5m/min～1.5m/min之间连续可调。电机3均由一个变频器5来驱动，以保持所有摩擦轮4的转速一致，从而使桩腿1在摩擦轮4上平稳的等速均匀旋转，将去除圆柱形桩腿焊缝的残余应力的过程变得快速准确且不间断，提高工作效率。A cylindrical leg weld residual stress relief device, as shown in Figure 1, includes a base plate 6, a frequency converter 5, a motor 3, a friction wheel 4 and an impact head 2, the motor is symmetrically arranged on the base plate, and the frequency converter is also arranged on the On the bottom plate, the friction wheel is located on the motor, the cylindrical leg 1 is placed above the friction wheel 4, and the two impact heads 2 are symmetrically arranged on the inner wall or the outer wall of the leg 1, which is conducive to maintaining the balance of the internal stress of the leg. Avoid deformation of the legs during the removal of residual stress. As shown in Figure 2, the included angle between the impact head 2 and the weld surface of the cylindrical leg 1 is 90 degrees, and the position where the impact head 2 contacts the inner or outer wall of the cylindrical leg 1 is the impact point, and the impact point is located at the welding surface. Sew both sides. In the device of the present invention, there are four friction wheels 4, which are divided into two groups. The motor 3 adopts frequency conversion speed regulation to drive the friction wheels 4 to rotate, so that the linear velocity of the friction wheels 4 is continuous between 0.5m/min and 1.5m/min. adjustable. The motors 3 are all driven by a frequency converter 5 to keep the rotating speeds of all the friction wheels 4 consistent, so that the legs 1 can rotate smoothly and uniformly on the friction wheels 4, and the residual stress of the welding seam of the cylindrical legs will be removed. Processes become fast, accurate and uninterrupted, increasing productivity.
该装置适用于外径范围为2m～10m的圆柱形桩腿，适用范围广，结构简单，能够有效的消除桩腿焊缝残余应力。The device is suitable for cylindrical pile legs with an outer diameter ranging from 2m to 10m, has a wide application range and a simple structure, and can effectively eliminate the residual stress of the welding seam of the pile legs.
优选地，该装置的冲击头为高效超声冲击头。Preferably, the impact head of the device is a high-efficiency ultrasonic impact head.
由于桩腿属于超长超大件，一般采取分段加工再焊接合拢的制造工艺，所以一个桩腿上存在多个焊缝，即本发明的装置可纵向或横向排列多个以适应桩腿长度及摆放方向，并将多个冲击头对称设置在相应的焊缝表面上分段进行去除残余应力操作。Since the pile legs are super long and super large pieces, the manufacturing process of segmental processing and welding is generally adopted, so there are multiple welds on one pile leg, that is, the device of the present invention can be arranged vertically or horizontally to adapt to the length and height of the pile leg. Arrange the direction, and arrange multiple impact heads symmetrically on the corresponding weld surface to remove residual stress in sections.
更进一步，可以制造加长型的圆柱形桩腿焊缝残余应力消除装置，设置多个电机和摩擦轮在底板上，保证桩腿匀速旋转，并将多个冲击头对称设置在相应的焊缝表面上，同时或分段对圆柱形桩腿上的多个焊缝进行去除残余应力工作。Furthermore, it is possible to manufacture an elongated cylindrical leg weld residual stress relief device, set multiple motors and friction wheels on the bottom plate to ensure that the leg rotates at a constant speed, and set multiple impact heads symmetrically on the corresponding weld surface On the other hand, the residual stress relief work is carried out on multiple welds on the cylindrical leg at the same time or in sections.
本发明的另一实施方式中提供了一种圆柱形桩腿焊缝残余应力消除方法，即将待焊接的圆柱形桩腿1平卧放置于四个摩擦轮3上，启动变频器5，驱动电机3运行，从而带动所有摩擦轮4旋转，使得桩腿1平稳的等速均匀旋转。电机3采用变频调速，驱动摩擦轮4转动，为保证所有摩擦轮4转速一致，所有电机均由一个变频器5来驱动。继续调节变频器5，使桩腿1旋转时的外圆面的线速度在0.5m/min～1.5m/min之间，例如1m/min。将两个冲击头2对称设置在桩腿1内壁，调整冲击头2与焊缝表面的距离为2mm，并呈90度夹角，启动冲击头2，在桩腿1转动时连续对称地冲击焊趾，对焊缝的残余应力进行消除。待桩腿1转动一周时，停止冲击和旋转，将两个冲击头2重新对称设置在桩腿1外壁，调整冲击头2与焊缝表面的距离为2mm，并呈90度夹角，再次启动冲击头2，在桩腿1转动一周后，停止冲击和旋转，即完成了全部的残余应力消除操作。Another embodiment of the present invention provides a method for eliminating the residual stress of a cylindrical leg weld, that is, placing the cylindrical leg 1 to be welded on the four friction wheels 3 in a horizontal position, starting the frequency converter 5, and driving the motor 3 runs, thereby driving all the friction wheels 4 to rotate, so that the pile leg 1 rotates smoothly and uniformly at a constant speed. Motor 3 adopts frequency conversion speed regulation to drive friction wheel 4 to rotate. In order to ensure that all friction wheels 4 rotate at the same speed, all motors are driven by a frequency converter 5 . Continue to adjust the frequency converter 5 so that the linear velocity of the outer circular surface of the leg 1 when it rotates is between 0.5m/min-1.5m/min, for example 1m/min. Set the two impact heads 2 symmetrically on the inner wall of the pile leg 1, adjust the distance between the impact head 2 and the weld surface to 2mm, and form an angle of 90 degrees, start the impact head 2, and continuously and symmetrically impact weld when the pile leg 1 rotates. Toe, to eliminate the residual stress of the weld. When the pile leg 1 rotates a circle, stop the impact and rotation, re-install the two impact heads 2 symmetrically on the outer wall of the pile leg 1, adjust the distance between the impact head 2 and the weld surface to 2mm, and make an included angle of 90 degrees, and start again The impact head 2 stops impacting and rotating after the pile leg 1 rotates for one revolution, that is to say, completes all residual stress relief operations.
优选地，该方法中采用的冲击头为高效超声冲击头。Preferably, the impact head used in the method is a high-efficiency ultrasonic impact head.
该方法同样适用于外径范围为2m～10m的圆柱形桩腿及加长型的圆柱形桩腿焊缝残余应力消除装置，操作十分方便，大大减轻了工人的劳动强度，利于实现自动化作业。The method is also applicable to the cylindrical leg with an outer diameter ranging from 2m to 10m and the elongated cylindrical leg weld residual stress relief device, which is very convenient to operate, greatly reduces the labor intensity of workers, and is beneficial to realize automatic operation.
本发明提供的一种圆柱形桩腿焊缝残余应力消除装置及方法，将冲击头对称布置，有利于保持桩腿内应力的平衡，避免在去除残余应力过程中引起桩腿的变形；还采用连续旋转的方式，可以快速且准确的对圆柱形桩腿焊缝的残余应力进行去除，大大增加了工作效率。且风电安装船圆柱形桩腿直径一般在2m以上，适用范围为广，故本发明的整个装置结构简单，方法便于操作，大大减轻了工人的劳动强度，有利于实现自动化作业。The invention provides a device and method for eliminating residual stress of cylindrical pile leg welds. The impact head is symmetrically arranged, which is beneficial to maintain the balance of internal stress of the pile leg and avoid deformation of the pile leg during the process of removing residual stress; The continuous rotation method can quickly and accurately remove the residual stress of the welding seam of the cylindrical leg, which greatly increases the work efficiency. Moreover, the diameter of the cylindrical leg of the wind power installation ship is generally more than 2m, and the application range is wide. Therefore, the whole device of the present invention has a simple structure, and the method is easy to operate, which greatly reduces the labor intensity of workers and is conducive to the realization of automatic operation.
上述说明示出并描述了本发明的优选实施例，如前所述，应当理解本发明并非局限于本文所披露的形式，不应看作是对其他实施例的排除，而可用于各种其他组合、修改和环境，并能够在本文所述发明构想范围内，通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围，则都应在本发明所附权利要求的保护范围内。The foregoing description shows and describes preferred embodiments of the present invention, and as previously stated, it is to be understood that the present invention is not limited to the form disclosed herein and should not be construed as excluding other embodiments but may be applied to various other embodiments. Combinations, modifications and circumstances, and can be modified within the scope of the inventive concept described herein, by the above teachings or by skill or knowledge in the relevant field. However, changes and changes made by those skilled in the art do not depart from the spirit and scope of the present invention, and should all be within the protection scope of the appended claims of the present invention.
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