Scientific research and development is the driving force of enterprise development. After more than ten years of system reform, enterprises in the metal structure industry have a deep understanding of this. With the development of diversified market demand, users have higher and higher requirements for product functions and quality. In order to meet the requirements of users, enterprises have also increased their investment in science and technology and carried out technological innovation around the "satisfaction project". In view of the pattern of small batch production of heavy industry, enterprises increase technical input, promote the use of efficient welding technology, flux-cored wire and special welding machine, strengthen the development, research and application of special tooling to prevent welding deformation; Aiming at the small batch and specialized production mode in petrochemical industry, the enterprise is equipped with automatic blanking equipment, automatic or semi-automatic welding special plane and automatic post-welding processing line.
2. 1 Progress of welding technology in heavy ore industry
Aiming at the market development prospect and improving the added value of products, heavy mining enterprises have developed high-tech products such as coal deep processing products, train shafts for high-speed trains and large keyless oil film bearings. From 1999 to 2000, Taiyuan Heavy Machinery Group Co., Ltd. won the first place in the world with four high technical contents and great manufacturing difficulties: Ningbo Julong piercing mill, Three Gorges 1200-ton bridge crane, Liaoyuan 7500-ton horizontal extruder and Shenzhen Century Window rotating stage. Welding technicians use advanced computer simulation methods of structural deformation and years of experience in controlling welding deformation to accumulate knowledge, thus ensuring products. Aiming at the market development trend, the technicians of Dalian Heavy Industry Group Co., Ltd. cooperated with the Welding Institute of the Research Institute of the Ministry of Metallurgy in Beijing to develop the surface spray welding technology of large rolls and provide batch repair products for Angang, forming an annual production capacity of 600 pieces, forming a sustainable development trend. The technicians of China No.1 Tractor Construction Machinery Company developed a computer-controlled tractor, a double-head CO2 gas shielded automatic welding machine with shift shaft and a double-head CO2 gas shielded automatic welding machine with tractor roller, and applied virtual technology to generator testing.
Enterprises in heavy mining industry pay attention to product quality and benefit, and vigorously promote new technologies and new processes.
① Popularization and application of new fuel flame cutting technology: Through the research and market research on the flame cutting technology of Ruiqi, Kaiteng gas and new metal cutting gas, through a large number of cutting experiments and comparative studies, according to the principle that new fuel is not easy to backfire, and through reasonable adjustment of cutting process parameters, high-speed nozzles and other technical measures, the new fuel flame cutting technology has been successfully popularized, ensuring smooth cutting surface and high cutting accuracy of parts, and reducing the comprehensive cutting cost by 40%~45%.
② Popularization and application of high alloy composite strengthening welding technology: According to the requirements of surface hardening of some products, combined with the popularization and application achievements of new flux-cored wire and alloy solid-core wire and a lot of experimental research work, the repair and manufacture of shaft, gear, bucket tooth and die products have been successfully popularized, which not only ensures the requirements of parts recycling, but also greatly reduces the manufacturing cost.
③ Research and application of quantitative simulation of box girder welding deformation: Through joint research with Tsinghua University, the factors affecting box girder structural deformation from parts preparation to various welding processes are simulated by computer, and compared with the measured results. The simulation calculation module is modified again, and the simulation results are revised by using the experimental structural beam. The local test is carried out in the manufacture of the main beam of the Three Gorges 1200T bridge, and good results are obtained. At present, the project is still under study, and it is expected to form a box beam structure system through computer virtual manufacturing, which is of practical significance to guide production.
(4) Research on the surface flame spray welding technology of thick-walled conveying roller: Through the transformation of powder spraying system, special tooling and supporting equipment were developed, the remelting system was redesigned and manufactured, the key technology of "remelting" was solved, and the spray welding of special conveying roller for wide and thick plate mill was successfully completed.
⑤ Research on the application of arc welding robot: Through research, the programming technology of robot basic parts has been mastered, the key points such as the coordinated control of robot external axis have been solved, and the welding process specification parameters that meet the characteristics of robot welding have been formulated.
③ Research on automatic tracking technology of high-speed submerged arc welding: According to the welding requirements of its own products, the automatic tracking research of submerged arc welding was carried out, which improved the welding quality and work efficiency.
⑥ Special welding machine: Combined with the low-cost welding automation of products, a special automatic welding machine with double-head CO2 gas protection was developed, including computer-controlled tractor, shift shaft and tractor roller.
⑦ Application of Virtual Technology in Generator Testing
(8) Popularization and application of energy-saving, high-efficiency and consumption-reducing welding technologies such as friction welding and electron beam welding.
2.2 Progress of welding technology in petrochemical industry
Combined with the development of the industry, oil and gas pipeline construction enterprises vigorously promote the following new technologies and processes.
① Low hydrogen covered electrode downward welding technology: It has been applied in Shaanxi, Beijing and gas transmission pipeline project.
②STT semi-automatic welding technology: STT semi-automatic welding equipment was imported from Lincoln Company. On the basis of a large number of experiments, this technology is applied to the welding of large-diameter long-distance pipelines. In the Sultanate oil pipeline project, more than 20,000 passes Ф 711mm were welded.
③ All-position automatic welding technology of solid wire gas shielded welding: By introducing and absorbing this technology, it has been successfully applied in Hongkong-Beijing gas transmission pipeline project and gas transmission pipeline project (X70 test section).
④ All-position automatic welding technology of flux-cored wire gas shielded welding: This technology was introduced and applied to the welding of large storage tanks.
Combined with the development of the industry, chemical construction enterprises vigorously promote the following new technologies and processes. Registered structural engineer examination
① Popularization and application of new welding technologies: including automatic welding technology of spherical tank, submerged arc welding technology of circumferential seam of storage tank, hydraulic lifting inversion technology of cylindrical storage tank with automatic welding technology, double-sided synchronous argon arc welding technology of aluminum and stainless steel equipment, downward welding technology of long-distance pipeline, hot-melt butt welding technology of natural gas PE pipe, welding technology of stainless steel thin-walled pipe and brazing technology of copper pipe.
② Application of new installation technology: In the field assembly and welding of spherical storage tanks, advanced assembly technologies include: plug-in, pull-wire, bulk assembly, ground assembly and welding into large pieces, platform assembly and welding after installation, long-distance overall relocation, etc. This technology has been approved by the former Ministry of Chemical Industry. In the installation and construction of cylindrical storage tanks, there are mechanical lifting erection technology, mechanical lifting inversion technology, air-top inversion technology (obtaining the construction method), water floating erection technology (obtaining the construction method of the former Ministry of Chemical Industry) and hydraulic lifting inversion technology. Among them, the hydraulic lifting flip-chip technology won the national patent technology (patent number ZL93 1065763) in the name of "welding positioning device for cylindrical metal containers". This technology has the advantages of safety, reliability, economy and practicality, which is beneficial to improve the assembly and welding quality and production efficiency.
③ Heat treatment technology: In the heat treatment of large equipment and spherical tank welds, the post-weld heat treatment technologies of fuel method, gas method and electric heating method were successfully developed and applied, and the construction methods were obtained.
2.3 Progress of welding technology in other industries
Container specialized production enterprises, the production organization form is assembly line operation, and the main new welding technologies are the application of high-speed welding and corrugated plate copying welding.