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In the shipbuilding industry, the automation of carbon dioxide (CO2) cross-welding technology has always been a technical difficulty. Guangzhou Zhongchuan Longxue Shipbuilding Co., Ltd. broke the tradition, developed new equipment, and innovated the welding process, successfully developed a fully automatic double-wire CO2 transverse welding technology. This technology provides technical support for shipbuilding enterprises to improve welding quality and shorten shipbuilding cycle. At present, China Shipbuilding Longxue Company and Shenzhen Ruiling Industrial Co., Ltd. jointly applied for invention patents.
According to Zhao Zaiyu, chief welding technician and senior engineer of Longxue Shipbuilding Co., Ltd., in China's shipbuilding industry, CO2 semi-automatic gas shielded welding has been widely used, but because it is semi-automatic welding, it has high skill requirements for welders, and its process and operation technology. It has a great influence on the welding quality. If the operation is improper, the surface quality of the weld is poor and the qualified rate of flaw detection is low. Not only that, because domestic shipbuilding companies generally adopt single-sided CO2 semi-automatic pad welding process in the horizontal welding position, there is a big gap between the welding quality and the advanced shipbuilding countries. After the first construction, 30% to 50% of the horizontal welding position detection results Failure to meet the requirements, resulting in a large number of repair work, seriously affecting the dock cycle, bringing losses to the enterprise. "If you can use automated equipment instead of semi-automatic manual welding, it will greatly reduce welding defects." Zhao Zaiyu said. However, the fully automated CO2 horizontal welding technology has not only promoted application records in other domestic shipping companies, and there is no relevant information abroad. Therefore, if the semi-automatic welding of CO2 cross-welding can be successfully improved to a fully automated level, it will be a major advancement in shipbuilding welding technology.
In order to improve the welding quality and efficiency of the horizontal welding position, Longxue Shipbuilding Co., Ltd. is determined to overcome the technical problem of automatic double-wire CO2 cross-welding. Through technical cooperation with equipment manufacturers, the company finally successfully developed a set of double-wire CO2 automatic horizontal welding special equipment, and after many process tests, mastered the welding process. According to Zhao Zaiyu, the feature of automatic double-wire CO2 cross-welding is that there is one more welding torch on the same walking trolley. The structure is only one more welding torch than the single-wire horizontal welding machine; the support of the two welding guns can be adjusted freely. It can meet the welding requirements of various angles, and can also perform independent swing of a certain range; the combination of the walking trolley and the guide rail adopts the gear structure to ensure the stability and uniform speed of the walking; the back of the guide rail is fixed by magnets, which can be closely connected with the hull, and the guide rail can be Flexible bending is made to facilitate the welding of the hull curve line position. According to statistics, after the automatic double-wire CO2 horizontal welding equipment and technology, the welding efficiency is more than doubled compared with the traditional method, and the welding quality is guaranteed, the welder's labor intensity is reduced, and the repair cost and time are saved.
In order to ensure the effective service of the automatic double-wire CO2 horizontal welding equipment and process after successful development, Zhongchuan Longxue has developed the “R&D-Test-Application†process and strictly controls every aspect of the process. To this end, on the basis of previous research and experiments, the craftsman submitted the application for the evaluation of the welding procedure to the China Classification Society and the Norwegian Classification Society after preliminary mastering of the relevant technology of the double-wire transverse welding, and passed the one-off application. The certification of two classification societies. Subsequently, the company began to apply it to actual production. Because the test environment of the process evaluation is very different from the production environment, the company has developed a detailed application plan: first, finalize the list of operators, and then conduct training tests. Only after the test is passed can the site be operated. The test position was selected on the side of the oversized oil tanker built by the company and the lower joint of the crotch section. The X-ray inspection of the weld was performed after each welding. Practice has proved that the automatic double-wire CO2 cross-welding welding quality is stable. Not long ago, Longxue Shipbuilding Co., Ltd. also worked with equipment manufacturers to optimize the structure of the horizontal welder, such as the installation of windshield plates, fixed fixtures, etc., so that the welder can better serve the production.
According to Zhao Zaiyu, chief welding technician and senior engineer of Longxue Shipbuilding Co., Ltd., in China's shipbuilding industry, CO2 semi-automatic gas shielded welding has been widely used, but because it is semi-automatic welding, it has high skill requirements for welders, and its process and operation technology. It has a great influence on the welding quality. If the operation is improper, the surface quality of the weld is poor and the qualified rate of flaw detection is low. Not only that, because domestic shipbuilding companies generally adopt single-sided CO2 semi-automatic pad welding process in the horizontal welding position, there is a big gap between the welding quality and the advanced shipbuilding countries. After the first construction, 30% to 50% of the horizontal welding position detection results Failure to meet the requirements, resulting in a large number of repair work, seriously affecting the dock cycle, bringing losses to the enterprise. "If you can use automated equipment instead of semi-automatic manual welding, it will greatly reduce welding defects." Zhao Zaiyu said. However, the fully automated CO2 horizontal welding technology has not only promoted application records in other domestic shipping companies, and there is no relevant information abroad. Therefore, if the semi-automatic welding of CO2 cross-welding can be successfully improved to a fully automated level, it will be a major advancement in shipbuilding welding technology.
In order to improve the welding quality and efficiency of the horizontal welding position, Longxue Shipbuilding Co., Ltd. is determined to overcome the technical problem of automatic double-wire CO2 cross-welding. Through technical cooperation with equipment manufacturers, the company finally successfully developed a set of double-wire CO2 automatic horizontal welding special equipment, and after many process tests, mastered the welding process. According to Zhao Zaiyu, the feature of automatic double-wire CO2 cross-welding is that there is one more welding torch on the same walking trolley. The structure is only one more welding torch than the single-wire horizontal welding machine; the support of the two welding guns can be adjusted freely. It can meet the welding requirements of various angles, and can also perform independent swing of a certain range; the combination of the walking trolley and the guide rail adopts the gear structure to ensure the stability and uniform speed of the walking; the back of the guide rail is fixed by magnets, which can be closely connected with the hull, and the guide rail can be Flexible bending is made to facilitate the welding of the hull curve line position. According to statistics, after the automatic double-wire CO2 horizontal welding equipment and technology, the welding efficiency is more than doubled compared with the traditional method, and the welding quality is guaranteed, the welder's labor intensity is reduced, and the repair cost and time are saved.
In order to ensure the effective service of the automatic double-wire CO2 horizontal welding equipment and process after successful development, Zhongchuan Longxue has developed the “R&D-Test-Application†process and strictly controls every aspect of the process. To this end, on the basis of previous research and experiments, the craftsman submitted the application for the evaluation of the welding procedure to the China Classification Society and the Norwegian Classification Society after preliminary mastering of the relevant technology of the double-wire transverse welding, and passed the one-off application. The certification of two classification societies. Subsequently, the company began to apply it to actual production. Because the test environment of the process evaluation is very different from the production environment, the company has developed a detailed application plan: first, finalize the list of operators, and then conduct training tests. Only after the test is passed can the site be operated. The test position was selected on the side of the oversized oil tanker built by the company and the lower joint of the crotch section. The X-ray inspection of the weld was performed after each welding. Practice has proved that the automatic double-wire CO2 cross-welding welding quality is stable. Not long ago, Longxue Shipbuilding Co., Ltd. also worked with equipment manufacturers to optimize the structure of the horizontal welder, such as the installation of windshield plates, fixed fixtures, etc., so that the welder can better serve the production.
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