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Automatic welding of the tube head of the high pressure heater

Release time:

2025-07-15

Core process and technical key points:

System composition:

Equipment: Typically, a six-axis industrial robot (such as ABB or FANUC) is used, combined with TIG (Tungsten Inert Gas Shielded Welding) or laser welding systems, suitable for high-pressure pipe materials (such as stainless steel SA-213 or alloy steel). The system includes an automatic wire feeding mechanism, rotating fixtures (for fixing the pipe head), and control software (such as RoboDK or Siemens NX).

Working principle: The robot precisely controls the welding gun path according to the preset program (based on the CAD model), completing the pipe head weld seam (common types are ring weld or butt weld). The welding parameters (such as current, voltage, and speed) are automatically adjusted to ensure uniform penetration and no cracks (especially in high-pressure environments).

Key advantages:

High quality: Automation reduces human errors, with weld seam consistency reaching over 99%, meeting standards for high-pressure equipment (such as pressure testing requirements).

Efficiency improvement: Compared to manual welding, the speed can be increased by 40-60%, suitable for batch production or maintenance scenarios.

Safety: Avoids workers' exposure to high temperatures, arc light and high-pressure risks.

Cost-effectiveness: Long-term reduction in rework rate, decreased maintenance costs (especially for frequently replaced heater components).

Implementation suggestions:

Equipment selection: Recommend a robot system specifically for pipeline welding (such as KUKA's ArcTech series), with a cost of approximately 30-600,000 RMB. For small-scale projects, consider leasing or outsourcing to a professional welding factory (such as local industrial service providers).

Process flow:

Preparation stage: Clean the surface of the pipe head (remove oil stains, oxide layer), select matching welding wire (such as ER309L for stainless steel).

Operation stage: The robot automatically positions itself, performs multi-layer welding (takes about 2-5 minutes per pipe head), and conducts non-destructive testing (such as X-ray or penetrant testing) after welding.

Ensure material compatibility: The high-pressure heater tubes must be corrosion-resistant and withstand high pressure. Verify the material certificates before welding.

Compliance: Follow industry standards (such as ASME Section IX), and it is recommended to consult certification agencies (such as TUV or local quality inspection departments).

Optimization suggestions: Use simulation software (such as ANSYS) to simulate the welding thermal deformation to avoid affecting the equipment performance.

Industry application:

It is commonly used in the maintenance or manufacturing of high-pressure heaters in power plants. Automatic welding can extend the equipment lifespan and reduce the risk of leakage.