储罐倒装埋弧自动横焊机的改进研发

储罐倒装埋弧自动横焊机的改进研发刘恒毅

（新疆克拉玛依市工信局，新疆克拉玛依834000）

某公司在发展大型储罐倒装法施工技术的过程中遇到难题，由于储罐壁板内侧有顶升液压缸挡摘要：

着，罐壁内环缝焊接无法使用传统的储罐倒装埋弧自动横焊机，只能进行半自动焊接，影响整体焊接工效和质量。另外，传统储罐倒装埋弧自动横焊机较高，为了保证焊机操作空间，储罐抗风圈、加强圈等结构件只能在第二层罐壁板高度位置安装，安装高度2.5~5m，施工安全性差；储罐倒装埋弧自动横焊机焊接轨道固定在罐底部上，用手动摇柄机构调节焊枪上下操作困难。通过改进研发储罐倒装埋弧自动横焊机机架结构、焊剂收集送料系统和电动调节横梁装置等，解决了这些难题，有效提升了储罐的焊接质量和安装效率。

内环缝储罐倒装法；埋弧横焊机；焊剂；关键词：

TG433月中图分类号：文献标志码：

10.7512/j.issn.1001-2303.2020.05.23阅韵陨：

员园园员原圆猿园猿（圆园20）05原园111-03文章编号：

0前言

采用大型储罐倒装法施工工艺时，由于储罐壁

传统的储罐倒装板内侧的顶升液压缸占据位置[1]，

埋弧自动横焊机只能焊接储罐外侧环缝，罐壁内侧环缝侧采用半自动焊接，影响整体焊接工效和质量[2]。另外，传统储罐倒装埋弧自动横焊机较高，为了保证焊机操作空间，储罐抗风圈、加强圈等结构件只能安装在第二层罐壁板高度位置，安装高度2.5~5m，

储罐倒装埋弧自动横焊机施工安全性差、工效低[3]；

焊接轨道固定在罐底部，水平误差大，用手动揺柄机构调节焊枪上下操作比较困难[4]。为此，对储罐倒装埋弧自动横焊机进行改进设计，现场应用达到预期效果。

的数十台顶升液压缸[5]。

改进研发方案是将传统储罐倒装埋弧自动横焊机的方正框架结构的机架下部设计缺口，呈倒“L”结构，如图1所示。同时，将液压缸的稳定支撑改成可快速拆卸的活动支撑。液压缸下降后，拆除活动支撑，焊机的倒“L”机架可以避开液压缸，实现正常连续焊接，如图1~图3所示。

通过改进储罐倒装埋弧自动横焊机的机架结构，解决了传统储罐倒装埋弧自动横焊机无法焊接内环缝的难题，现场应用后，焊接效率和质量得到了大幅提高。

2焊剂收集送料系统改进研发

针对焊机高度较高的问题，分析发现由于要避开液压缸，焊机支架高度不能降低，只能降低焊机上部高度。而焊机上部的焊剂桶占用了较大空间，焊机下部支架内留有较大空余。将焊剂桶移至焊机下部支架内，可以有效降低焊机高度。

为此需要研制一套新的焊剂收集送料系统。将焊机顶部的焊剂桶移至机架下部，焊机上部加装焊剂斗（容积15L），下部焊接桶内的焊剂用气动输送至小焊剂斗，焊剂斗中安装感应式开关，自动控制

耘造藻糟贼则蚤糟宰藻造凿蚤灶早酝葬糟澡蚤灶藻窑窑1111焊机的机架结构改进研发

分析传统储罐倒装埋弧自动横焊机无法焊接

储罐内侧焊缝的问题，发现要实现储罐倒装法施工横缝内侧自动焊接，必须避让在储罐内侧圆周均布

收稿日期院2019-11-06；修回日期院20圆园-园猿-员愿

作者简介院刘恒毅（1976—），男，硕士，高级工程师，主要从事

油气田地面建设焊接技术的研究工作。E-mail：

118090707@qq.com。

焊接设备

图1

改进后的机架结构示意

Fig.1

Structurediagramofimprovedframeofautomatic

transverseweldingmachine

图2

改进后的自动焊机焊接储罐内侧焊缝Fig.2

Improvedautomaticweldingmachineforwelding

innerweldoftank

上料，如图4所示。这样，焊工可在地面加装、清空焊剂，提高了操作的安全性。

焊剂用量为

G式中GSS为单位时间焊=剂ksv用量酌

（单位：kg/s）；k为波

112窑耘造藻糟贼则蚤糟宰藻造凿蚤灶早酝葬糟澡蚤灶藻第50卷

图3

改进后的自动焊机焊接储罐外侧焊缝

Fig.3

Improvedautomaticweldingmachineforwelding

outerweldoftank

图4焊剂收集送料系统示意

Fig.4Schematicdiagramoffluxcollectionandfeeding

system

动0.004系数m，取1.5；s为托带轮上焊剂堆高截面积，取

2；v为最大焊接速度，取0.02m/s；酌为焊剂容重，取1100kg/m3。计算可得，G风量为

S=0.132kg/s。

Q0=滋G籽S式中Q0为气力输送风量；滋为料气混合比，取2；籽0.055为空气210mm密度，取1.2kg/m3。经计算可得，风量Q33/h/s、功率，即1981.5mkW3/h，因系统末端有0=焊机的焊中压工业剂鼓收风集机滤[6]。

尘袋，选用综上，通过改进送料系统，焊机高度降低了0.8m，可以避让储罐上的加强圈、抗

窑焊接设备刘恒毅：储罐倒装埋弧自动横焊机的改进研发第5期风圈等结构件。储罐结构件可在底层安装到罐体上，

安装高度由2.5~5m降至0.8~2m，施工安全、质量和工效均得到大幅提高。同时，焊工可在地面加装、清空焊剂，提高了操作的安全性，如图5所示。

图5

改进后倒装埋弧自动横焊机应用

Fig.5Applicationofimprovedinvertedsubmergedarcau-tomatictransverseweldingmachine

3焊机电动横梁调节装置的改进研发

储罐倒装法施工埋弧自动横焊机的焊接轨道

固定在罐底上，焊接轨道水平方向误差大，用手动

揺柄调节机构调节焊枪上下，焊工的操作难度大，经常有误操作（摇反方向，焊枪上下偏离增加），影

响焊接质量。

针对该问题，采用电动横梁调节装置代替传统的手摇调节装置。将固定焊机托带轮、焊枪的横梁加装上下电动调节丝杆和导柱，焊工通过有线控制手柄调节横梁高度，实现焊剂托带轮和焊枪高度的上下调节。

通过改进调节装置，提高了焊接操控精度，有效降低了焊工的劳动强度，提高了焊接质量。

4结论

文中研发的储罐倒装内外两用埋弧自动横焊机实现了储罐倒装施工内环缝的自动焊接。通过改变焊机的机架结构，规避罐内壁周围的液压缸，实现了罐内壁的自动焊接；降低了焊机焊枪上部高度，解决了储罐抗风圈、加强圈等结构无法在底层高度安装的问题；加装电动横梁调节，提升了焊机的可操作性和焊接质量。该设备已成功应用于多座10m3储罐中，解决了施工难题，效果良好，推动了大型储罐倒装法施工技术的发展。

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