【作者】 陈建平；

【导师】 胡绳荪；

【作者基本信息】 天津大学 ， 材料加工工程， 2013， 博士

【摘要】 随着管道建设的高速发展，带动了管道施工设备的迅猛发展。在管道运输中，管道焊接质量的高低，直接关系着管道运输的高效率和安全性，它是管道施工中的一个重要环节。目前药芯焊丝半自动焊以焊接合格率和生产效率高等优势，在我国大、中型口径长距离输运管道建设中得到广泛应用，是目前我国长输管线建设中最常用的焊接方法。焊接工程车作为管道半自动焊接流水化作业不可缺少的工程机械，是提高管道施工效率，降低施工成本的重要施工机械，受到管道施工装备研究人员的重视，如何进一步提高焊接工程车的效率，节能减排，满足更加严格的国内外环境保护法律法规，已成为该领域亟待解决的问题之一。本文介绍了新型节能静音型焊接工程车的研制。该焊接工程车的设计与研制中，深入分析了现有焊接工程车的优缺点，结合油气管道焊接施工的实际需要，充分利用新技术、新工艺和新材料，使新型焊接工程车具有了节能、静音以及运输方便等特点。首先是研究分析了行走系统、随车起重系统、发电焊接系统，确定了发动机、发电焊接一体机、随车起重机、行走系统之间高效的动力传动方式，实现了焊接工程车的模块化设计，提高了设备运行的可靠性，并且达到了节能、降噪的效果。其次是对焊接工程车的结构进行了优化，缩减了焊接工程车的宽度，并采用多体系统动力学仿真软件RecurDyn (Recursive Dynamic)对焊接工程车不同工况稳定性等进行了静力学、动力学的数值模拟仿真，确定了焊接工程车的结构设计。三是结合焊接工程实际，应用发电焊接一体机进行了相关的焊接工艺试验，并结合焊接过程出现的问题，对发电焊接一体机进行了改造，使其满足了多工位管道焊接的要求。最后，通过工业性实验评价，对新研制的节能静音型一体化焊接工程车的节能静音效果、整机稳定性、可靠性等进行了验证。实验表明，节能静音型一体化焊接工程车达到了设计的要求，能耗减少40%，工作时噪音低于70dB，最大吊重、爬坡时，整机稳定性良好。更多还原

【Abstract】 The high speed development of pipeline construction leads to the rapiddevelopment of pipeline construction equipment. In the pipeline transportation, thewelding quality of pipes is directly related to the pipeline efficiency and safety, so it isa important segment of the pipeline construction.At present flux-cored wire semi-automatic welding has advantages of highwelding qualified rate and production efficiency, so it has been the most commonwelding method used in the construction of long distance pipeline and widely appliedin the construction of big, medium-sized diameter transport pipelines in China.As indispensable engineering machinery in the assembly line of semi-automaticwelding of pipelines, mobile welding workshops are valued by researchers to furtherimprove the welding efficiency, energy conservation and emission reductions and tomeet more strict environmental protection laws and regulations in China and abroad,which has become one problem to be solved in the field.This paper introduces the development of a new type energy-saving and quietmobile welding workshop. After analysing the advantages and disadvantages of theexisting mobile welding workshops, combining with the actual needs of oil and gaspipe welding construction, new technology and new material are made full use of tomake new mobile welding workshop to have characteristics of energy saving, lownoise and convenient for transportation.Firstly, travelling system, accessory lifting system, power generation weldingsystems are studied and analyzed, and the high efficient power transmission methodof the engine, power generation and welding all-in-one machine, accessory crane, andtravelling system is determined, which realizes the modular design of mobile weldingworkshop and improves the reliability of the equipment operation with the results ofenergy saving and noise reduction.Secondly, the structure of the mobile welding workshop is optimized. The widthis reduced and the multibody system dynamics simulation software RecurDyn(Recursive Dynamic) is used to do the numerical simulation analysis of the mobilewelding workshop’s stability in the different operating modes. The structural design ofthe mobile welding workshop is confirmed. Thirdly, combining with the welding engineering facts, experiments of weldingtechnique are carried out by using the power generation and welding all-in-onemachine. According to the problems found in the tests, the power generation andwelding all-in-one machine is reformed to satisfy the requirements of multistage pipewelding.Finally, the energy saving and silenced effects, stability and reliability of thedeveloped energy saving and silenced integrated mobile welding workshop areverified through industrial experiment evaluation. Results of the experiments showthat the energy saving and silenced integrated mobile welding workshop can meet thedesign requirements. Energy consumption is reduced by40%, and the noise at work isbelow70dB. The stability is still good when it climbing with the largest crane heavy.更多还原