CN106141375A - A kind of large-scale supporting roller built-up welding work station and operational approach thereof - Google Patents
A kind of large-scale supporting roller built-up welding work station and operational approach thereof Download PDFInfo
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- CN106141375A CN106141375A CN201610696123.2A CN201610696123A CN106141375A CN 106141375 A CN106141375 A CN 106141375A CN 201610696123 A CN201610696123 A CN 201610696123A CN 106141375 A CN106141375 A CN 106141375A
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- type heating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
- B23K37/0461—Welding tables
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
- B23K9/044—Built-up welding on three-dimensional surfaces
- B23K9/046—Built-up welding on three-dimensional surfaces on surfaces of revolution
- B23K9/048—Built-up welding on three-dimensional surfaces on surfaces of revolution on cylindrical surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/10—Other electric circuits therefor; Protective circuits; Remote controls
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Arc Welding In General (AREA)
Abstract
The present invention relates to a kind of large-scale supporting roller built-up welding work station and operational approach thereof, large-scale supporting roller built-up welding work station includes roller support means, roll driving apparatus, on-line heating system, welding system and flux restoring system, support roller and supported location by roller support means, and can being rotated by roll driving apparatus；The gate-type heating mantles of on-line heating system covers and is supporting formation enclosing cover outside roller, and cover body inwall is provided with heat-insulation layer and faradism heater, and welding gun can stretch in gate-type heating mantles cover body after vertically moving；Flux restoring system is set bottom gate-type heating mantles.In the present invention, supporting roller and heat in enclosing cover and be incubated, welding also can reclaim solder flux automatically while many bond pads mechanism, it is possible to realizes the preheating online of large-scale supporting roller, weld, be incubated and the continuous process such as temper；Easy to operate, automaticity is high, temperature controls accurately, be conducive to improving the surfacing quality supporting roller, improve remediation efficiency, filled up the blank of this technology.
Description
Technical field
The present invention relates to large-scale supporting roller technology for repairing surfacing field, particularly relate to a kind of large-scale supporting roller built-up welding work station
And operational approach.
Background technology
Along with present-day mill is to maximization, high speed, automation direction development, to supporting the requirement of roller the most increasingly
High.In actual production, support roller is one of vitals on each production line, and each heavy steel rolling mill will consume every year
These base parts a large amount of.In order to reduce production cost, extend the service life supporting roller, generally use the mode of roll surface built-up welding to propping up
Support roller is repaired so that it is can reuse.
For prior art, the Bead weld repair work difficulty of large-scale supporting roller is relatively big, and its Major Difficulties is to support roller
On-line heating problem, owing to being difficult to closed heating, expose aerial mode of heating and make it quickly dispel the heat, be difficult to
Reaching welding temperature, the welding below standard temperature makes support roller show stress change greatly, supports roller and easily go out in welding process
Existing slight crack, is welded into power the lowest.
Summary of the invention
The invention provides a kind of large-scale supporting roller built-up welding work station and operational approach thereof, possess adjustable support roller and prop up
Support and drive system, support roller and heat in enclosing cover and be incubated, and the welding simultaneously of many bond pads mechanism also can reclaim weldering automatically
Agent, it is possible to realize the preheating online of large-scale supporting roller, weld, be incubated and the continuous process such as temper；Easy to operate, certainly
Dynamicization degree is high, temperature controls accurately, is conducive to improving the surfacing quality supporting roller, improves remediation efficiency, filled up this skill
The blank of art.
In order to achieve the above object, the present invention realizes by the following technical solutions:
A kind of large-scale supporting roller built-up welding work station, including roller support means, roll driving apparatus, on-line heating system, welding
System and flux restoring system, support roller and supported location by roller support means, and can being rotated by roll driving apparatus；Institute
Stating on-line heating system and include gate-type heating mantles, gate-type heating mantles covers and is supporting formation enclosing cover, cover body inwall outside roller
Being provided with heat-insulation layer and faradism heater, set thermocouple in cover body, covering on top sets welding gun entrance；Position corresponding with welding gun entrance
The gate-type heating mantles top put sets welding system and infrared scanner, and wherein the welding gun of welding system can stretch into after vertically moving
In gate-type heating mantles cover body；Setting flux restoring system bottom gate-type heating mantles, flux restoring system includes vibrosieve, flux restoring
Box, solder flux machine for automatically recovering and solder flux storage tank, set movable hearth furnace bottom baffle bottom gate-type heating mantles, movable hearth furnace bottom baffle moves
Make to be formed bottom gate-type heating mantles welding slag dropping channel after Dong；Vibrosieve is placed in the lower section of welding slag dropping channel, vibrating screen mesh
Lower section sets flux restoring box, and flux restoring box connects solder flux storage tank by solder flux machine for automatically recovering.
Described roller support means is Anti-moving turning rolls, uses hydraulic pressure or Mechanical Driven.
Described roll driving apparatus is main spindle box；Main spindle box is provided with servomotor and huge revolving bearing, huge revolving axle
The inner ring held inlays large modulus gear ring and the meshed transmission gear on servo motor output shaft, and the inner ring of huge revolving bearing passes through
Scalable Hooks coupling universal coupling is connected transmission with heavy chuck, and heavy chuck is used for the support roller side roll neck that is installed.
Described main spindle box can vertical lift and along support roll axis direction move；Door-shaped frame it is provided with outside main spindle box, main
Axle box both sides set slide block and match with the guide rail on door-shaped frame column, and main spindle box top sets on screw and door-shaped frame crossbeam
Leading screw matches, and drives by being arranged on the lifting motor at door-shaped frame top, and main spindle box can realize vertical lift；At the bottom of main spindle box
Portion sets running mechanism, can move along supporting roll axis direction under the driving of running motor；Hand-worked lift is set bottom main spindle box,
It is locked after rising put in place at main spindle box.
Described gate-type heating mantles is at the bottom of by anterior cover body, middle part cover body, rear portion cover body, overhead gage, lower baffle plate and movable hearth furnace
Baffle plate collectively constitutes enclosed construction, and cover body two ends, middle part composition detachably connected with anterior cover body and rear portion cover body respectively is main
Cover body；Overhead gage and lower baffle plate, along horizontal median axis subdivision, form baffle plate after combination；Movable hearth furnace bottom baffle is 2 pieces, along cover body
Axisymmetrical is arranged, and can be respectively along moving with cover body axis vertical direction；The main cover body both sides of gate-type heating mantles are respectively mounted
Several pulleys, pulley is driven by reducing motor, and gate-type heating mantles main cover body can be driven to set along parallel with gate-type heating mantles axis
The slide put；Lower baffle plate and track are fixed on equipment base, and overhead gage is detachably connected with lower baffle plate.
Described middle part cover body is provided with different lengths specification, is respectively used to support the use when different size supports roller built-up welding.
Multiple thermal treatment zone, each thermal treatment zone it is divided into be respectively provided with faradism heater inside described gate-type heating mantles；Sense
Answering electric heater unit to be made up of resistor, iron staff and power supply, the resistor in each thermal treatment zone is according to the star of three-phase alternating current
Structural wiring；Iron staff is fixed on cover body through cover body heat-insulation layer, outside suit ceramic dustcoat；Resistor passes through with external power source
Iron staff is connected；The faradism heater of each thermal treatment zone controls respectively；Thermocouple, thermoelectricity it is respectively equipped with in each thermal treatment zone
Even, infrared scanner and faradism heater are connected with heating control system respectively, heating control system be single-chip microcomputer or
PLC。
Described welding system includes that array may move welding mechanism, and often the removable welding mechanism of group is by welding tractor, weldering
Rifle, welding gun moving apparatus, welding gun water cooling plant, welding wire conveying device, flux transport equipment form, and each assembly welding rifle connects weldering respectively
Gun controller.
The operational approach of a kind of large-scale supporting roller built-up welding work station, comprises the steps:
1) roller support means is located in the middle of gate-type heating mantles track, near main spindle box side；Large-scale supporting roller is lifted on
In roller support means, adjust carrying roller height and angle makes support roll shaft edema with the heart involved put down；Adjust headstock so that it is on heavy type four
Dog chuck is concentric with support roller, supports roller one end roll neck, the servomotor on main spindle box by heavy chuck fixing connection
Support roller can be driven to rotate；
2) according to the specification of support roller, select the length of cover body in the middle part of gate-type heating mantles, after installing main cover body, start main
The reducing motor of cover body both sides, moves to main cover body support above roller, and forms cover body together with overhead gage, lower baffle plate；Cover
Capping at welding gun entrance and viewing window, closes movable hearth furnace bottom baffle, makes gate-type heating mantles cover body be in closed state；
3) start the faradism heater of each thermal treatment zone, preheat and interlayer heating, firing rate supporting roller
Being set as 8～12 DEG C/h, when cover body temperature is 400～500 DEG C, reach preheating standard, preheating completes；
4) during welding, handle each welding gun and stretch in gate-type heating mantles cover body from welding gun porch, support roller at main spindle box
Rotating under driven by servomotor, velocity of rotation is 6～10min/ circles；During welding, many welding guns can simultaneously or independently work, every
Welding gun carries out built-up welding in respective region, until it reaches repair till requiring；Movable hearth furnace bottom baffle is opened by welding simultaneously, opens
Dynamic flux restoring system, the residue produced in welding process falls in vibrosieve naturally, and granule is little and the most unburned freezes
Agent, by entering in flux restoring box after vibrating screen mesh, enters weldering by pipeline under the suction function of solder flux machine for automatically recovering
Agent storage tank；When needing the solder flux in use solder flux storage tank, air compressor starts, utilizes malleation by solder flux storage tank
Reclaim in the welding flux box that solder flux injects in welding gun, the solder flux in welding flux box can be automatically injected in welding gun, it is achieved solder flux is again
Utilize；
5), during built-up welding, use infrared scanner to detect in real time supporting roller body of roll temperature, and the scanning body of roll is each continuously
The temperature of point draws temperature curve and colored thermograph；Arbitrarily it is divided into 3 sectors by supporting roller and then controls 3 regions
Temperature, when the temperature detected is less than setting value 400 DEG C, the faradism heater of corresponding region is actuated for adding automatically
Heat, till temperature is up to standard；Whole process uses PID close-loop control mode to carry out intelligent temperature control, until welding terminates；
6) carry out slow cooling for the first time after welding job completes, use the speed as programming rate to carry out slow cooling, slow cooling
Before Kai Shiing, welding gun being removed gate-type heating mantles, gate-type heating mantles cover body recloses；By using PID closed loop control, control cover
Internal cooling rate；
7), after slow cooling terminates for the first time, again heat supporting roller, with eliminate in welding process new resurfacing welding material and
Stress between original material, is allowed to more preferably merge by high-temperature process；Programming rate is 8～12 DEG C/h, when cover body temperature
Reach to stop heating when 550～580 DEG C, be incubated 15～20 hours；
8) slow cooling for the second time uses the mode as during slow cooling for the first time, until during case temperature≤50 DEG C, for the second time
Annealing process terminates, and now supports roll temperature close to room temperature；
9) close on-line heating system, remove both sides overhead gage, gate-type heating mantles main cover body is removed from supporting roller top,
The Bead weld repair process of whole support roller terminates.
Spiral or step-by-step movement built-up welding can be used, it is possible to individual pen boxing, the welding of axial straight line or spot welding filling-up hole during built-up welding；Root
Setting welding route according to welding process requirement, the voltage when starting the arc, receipts arc, built-up welding, wire feed rate and receipts arc time, by welding gun control
Device processed controls each welding gun and is automatically performed weld deposit process.
Compared with prior art, the invention has the beneficial effects as follows:
1) possess adjustable support roller support and drive system, use high-power servomotor to be driven, support roller with
Connected by scalable Hooks coupling universal coupling between main spindle box, there is staring torque big, speed-regulating range width, it is simple to controlling, regulation of mental activities is simple
Etc. advantage；Support roller use adjustable Anti-moving turning rolls support, it is to avoid occur skid, throw switch and cause welding deposition gold
Genus is rewelded, and catches up with the phenomena impair surfacing qualities such as heap out-of-flatness, stability of rotation when supporting roller built-up welding, does not creeps, does not throws switch, carries energy
Power is big, rotating torque is little, can stepless time adjustment；
2) on-line heating and insulation are realized automatically controlling by PID regulator+two-way controlled module, and robot control system(RCS) can be to online
Heating, attemperator monitor in real time and regulate, it is ensured that interlayer temperature during roll welding and quality；
3) built-up welding uses the moveable welding mechanism welding simultaneously of many groups, and wherein necked part is set by CMT pulsed cold welding
For completing, high-power water-cooling welding gun can realize long-time built-up welding continuously；Welding manner can use spiral or step-by-step movement built-up welding, also
Can individual pen boxing, axial straight line welding and spot welding filling-up hole；The voltage when starting the arc, receipts arc, built-up welding is preset according to welding process requirement,
Wire feed rate and receipts arc time, can be automatically adjusted, welding process continuous-stable, provide solid for large-scale roller surfacing quality
Guarantee；
4) can realize the automatic transport of the most multiple welding head solder flux, welding carries out Automatic sieve to solder flux and welding slag simultaneously
Divide and reclaim；
5) use intelligent full-automatic control system, large-scale supporting roller built-up welding work station is carried out comprehensive effective control automatically
System and automatically monitoring；The preheating online of large-scale supporting roller can be realized continuously, weld, be incubated and temper technical process, from
Dynamicization degree is high, and integration is good；
6) possess welding, drive, heat, flux delivery and reclaimer fault real-time detection alarming function, it is ensured that equipment
Operation safety and stability is reliable.
Accompanying drawing explanation
Fig. 1 is the front view of large-scale supporting roller built-up welding work station of the present invention.
Fig. 2 is the side view of large-scale supporting roller built-up welding work station of the present invention.
Fig. 3 is the front view of main spindle box of the present invention and portal frame.
Fig. 4 is the rearview of Fig. 3.
Fig. 5 is the top view of Fig. 3.
Fig. 6 is the side view of Fig. 3.
Fig. 7 is the A-A sectional view in Fig. 1.
Fig. 8 is the structural representation of gate-type heating mantles of the present invention.
Fig. 9 is the main pseudosection of gate-type heating mantles of the present invention.
Figure 10 is the cross-sectional view of gate-type heating mantles of the present invention.
In figure: 1. the heavy chuck 4. mobile work platform 5. of servomotor 2. main spindle box 3. supports roller 6.
Scalable Hooks coupling universal coupling 11. huge revolving of gate-type heating mantles 7. infrared scanner 8. Anti-moving turning rolls 9. track 10.
Bearing 12. door-shaped frame 13. running motor 14. lifting motor 15. large modulus gear ring 16. slide block 17. leading screw 18. can
Cover body 20-3. rear portion cover body 21. welding gun entrance in the middle part of mobile furnace bottom baffle plate 19. vibrosieve 20-1. front portion cover body 20-2.
22. overhead gage 23. lower baffle plate 24. pulley 25. reducing motor 26. iron staff 27. faradism heater 28. thermocouples
29. thermal treatment zone 30. window viewport 31. heat-insulation layer 32. blower fans
Detailed description of the invention
Below in conjunction with the accompanying drawings the detailed description of the invention of the present invention is described further:
As shown in Fig. 1-Fig. 2, it it is the structural representation of a kind of large-scale supporting roller built-up welding work station of the present invention.The present invention
Described a kind of large-scale supporting roller built-up welding work station, including roller support means, roll driving apparatus, on-line heating system, welding system
With flux restoring system, support roller 5 and supported location by roller support means, and can being rotated by roll driving apparatus；Described
On-line heating system includes that gate-type heating mantles 6, gate-type heating mantles 6 cover and is supporting formation enclosing cover, cover body inwall outside roller 5
Being provided with heat-insulation layer 31 and faradism heater 27, set thermocouple 28 in cover body, covering on top sets welding gun entrance 21；Enter with welding gun
Gate-type heating mantles 6 top of mouth 21 correspondence positions sets welding system and infrared scanner 7, and wherein the welding gun of welding system can hang down
Stretch in gate-type heating mantles 6 cover body after translation is dynamic；Setting flux restoring system bottom gate-type heating mantles 6, flux restoring system includes
Vibrosieve 19, flux restoring box, solder flux machine for automatically recovering and solder flux storage tank, set bottom gate-type heating mantles 6 and keep off at the bottom of movable hearth furnace
Plate 18, movable hearth furnace bottom baffle 18 makes to be formed bottom gate-type heating mantles 6 welding slag dropping channel after moving；Vibrosieve 19 is placed in welding slag
The lower section of dropping channel, sets flux restoring box below vibrosieve 19 screen cloth, flux restoring box is connected by solder flux machine for automatically recovering
Solder flux storage tank.
Described roller support means is Anti-moving turning rolls 8, uses hydraulic pressure or Mechanical Driven.(as shown in Figure 7)
As shown in figures 3 to 6, described roll driving apparatus is main spindle box 2；Main spindle box 2 is provided with servomotor 1 and large-scale time
Rotating shaft holds 11, and the inner ring of huge revolving bearing 11 is inlayed large modulus gear ring 15 and engaged biography with the gear on servomotor 1 output shaft
Dynamic, the inner ring of huge revolving bearing 11 is connected transmission, heavy type four paws by scalable Hooks coupling universal coupling 10 with heavy type chuck 3
Chuck 3 is used for the support roller 5 side roll neck that is installed.
Described main spindle box 2 can vertical lift and along support roller 5 axis direction move；It is provided with door-shaped frame outside main spindle box 2
12, main spindle box 2 both sides set slide block 16 and match with the guide rail on door-shaped frame 12 column, and main spindle box 2 top sets screw and door shape
Leading screw 17 on framework 12 crossbeam matches, and drives by being arranged on the lifting motor 14 at door-shaped frame 12 top, and main spindle box 2 can
Realize vertical lift；Set running mechanism bottom main spindle box 2, can move along supporting roller 5 axis direction under the driving of running motor 13
Dynamic；Set hand-worked lift bottom main spindle box 2, be locked after rising put in place at main spindle box 2.
As Figure 8-Figure 10, described gate-type heating mantles 6 is by anterior cover body 20-1, middle part cover body 20-2, rear portion cover body 20-
3, overhead gage 22, lower baffle plate 23 and movable hearth furnace bottom baffle 18 collectively constitute enclosed construction, and cover body 20-2 two ends, middle part are respectively
With anterior cover body 20-1 and rear portion cover body 20-3 detachably connected composition main cover body；Overhead gage 22 and lower baffle plate 23 are along level
Axis subdivision, forms baffle plate after combination；Movable hearth furnace bottom baffle 18 is 2 pieces, along cover body axisymmetrical arrange, and can respectively along with
Cover body axis vertical direction moves；The main cover body both sides of gate-type heating mantles 6 are respectively mounted several pulley 24, and pulley 24 is by the electricity that slows down
Machine 25 drives, and the track 9 that gate-type heating mantles 6 main cover body edge and gate-type heating mantles 6 axis can be driven to be arranged in parallel slides；Lower block
Plate 23 and track 9 are fixed on equipment base, and overhead gage 22 is detachably connected with lower baffle plate 23.
Described middle part cover body 20-2 is provided with different lengths specification, is respectively used to supporting when different size supports roller 5 built-up welding making
With.
It is divided into multiple thermal treatment zone 29, each thermal treatment zone 29 to be respectively provided with sense as it is shown in figure 9, described gate-type heating mantles 6 is internal
Answer electric heater unit 27；Faradism heater 27 is made up of resistor, iron staff 26 and power supply, the resistance in each thermal treatment zone 29
Band connects up according to the star structure of three-phase alternating current；Iron staff 26 is fixed on cover body through cover body heat-insulation layer 31, outside suit pottery
Porcelain housing；Resistor is connected by iron staff 26 with external power source；The faradism heater 27 of each thermal treatment zone 29 controls respectively；
Be respectively equipped with thermocouple 28 in each thermal treatment zone 29, thermocouple 28, infrared scanner 7 and faradism heater 27 respectively with add
Thermal control system connects, and heating control system is single-chip microcomputer or PLC.
Described welding system includes that array may move welding mechanism, and often the removable welding mechanism of group is by welding tractor, weldering
Rifle, welding gun moving apparatus, welding gun water cooling plant, welding wire conveying device, flux transport equipment form, and each assembly welding rifle connects weldering respectively
Gun controller.
The operational approach of a kind of large-scale supporting roller built-up welding work station, comprises the steps:
1) roller support means is located in the middle of gate-type heating mantles track 9, near main spindle box 2 side；Large-scale supporting roller 5 is lifted
In roller support means, adjust carrying roller height and angle makes support roller 5 axle center level；Adjust main spindle box 2 position so that it is on weight
Type chuck 3 is concentric with support roller 5, supports roller 5 one end roll neck, on main spindle box 2 by heavy chuck 3 fixing connection
Servomotor 1 can drive support roller 5 to rotate；
2) according to the specification of support roller 5, the length of cover body 20-2 in the middle part of gate-type heating mantles is selected, after installing main cover body,
Start the reducing motor 25 of main cover body both sides, move to main cover body support above roller 5, and together with overhead gage 22, lower baffle plate 23
Composition cover body；Cover the capping at welding gun entrance 21 and viewing window 30, close movable hearth furnace bottom baffle 18, make gate-type heating mantles 6
Cover body is in closed state；
3) start the faradism heater 27 of each thermal treatment zone 29, preheat and interlayer heating, heating supporting roller 5
Speed is set as 8～12 DEG C/h, when cover body temperature is 400～500 DEG C, reaches preheating standard, and preheating completes；
4) during welding, handle each welding gun and stretch in gate-type heating mantles 6 cover body at welding gun entrance 21, support roller 5 and leading
Axle box servomotor 1 is rotated by, and velocity of rotation is 6～10min/ circles；During welding, many welding guns can simultaneously or independently work,
Every welding gun carries out built-up welding in respective region, until it reaches repair till requiring；Welding is simultaneously by movable hearth furnace bottom baffle 18
Opening, start flux restoring system, the residue produced in welding process falls in vibrosieve 19 naturally, and granule is little and uniform
Unburned solder flux, by entering in flux restoring box after vibrosieve 19 screen cloth, passes through under the suction function of solder flux machine for automatically recovering
Pipeline enters solder flux storage tank；When needing the solder flux in use solder flux storage tank, air compressor starts, and utilizes malleation to weld
Reclaiming in the welding flux box that solder flux injects in welding gun in agent storage tank, the solder flux in welding flux box can be automatically injected in welding gun, it is achieved
Solder flux again with；
5), during built-up welding, use infrared scanner 7 to detect in real time supporting roller 5 body of roll temperature, and scan the body of roll continuously
The temperature of each point draws temperature curve and colored thermograph；Support roller 5 is arbitrarily divided into 3 sectors and then controls 3 districts
The temperature in territory, when the temperature detected less than setting value 400 DEG C time, the faradism heater 27 of corresponding region automatically start into
Row heating, till temperature is up to standard；Whole process uses PID close-loop control mode to carry out intelligent temperature control, until welding
Terminate；
6) carry out slow cooling for the first time after welding job completes, use the speed as programming rate to carry out slow cooling, slow cooling
Before Kai Shiing, welding gun being removed gate-type heating mantles 6, gate-type heating mantles 6 cover body recloses；By using PID closed loop control, control
Cooling rate in cover body；
7), after slow cooling terminates for the first time, again heat supporting roller 5, with eliminate in welding process new resurfacing welding material and
Stress between original material, is allowed to more preferably merge by high-temperature process；Programming rate is 8～12 DEG C/h, when cover body temperature
Reach to stop heating when 550～580 DEG C, be incubated 15～20 hours；
8) slow cooling for the second time uses the mode as during slow cooling for the first time, until during case temperature≤50 DEG C, for the second time
Annealing process terminates, and now supports roller 5 temperature near room temperature；
9) close on-line heating system, remove both sides overhead gage 22, by gate-type heating mantles 6 main cover body from supporting roller 5 top
Removing, the Bead weld repair process of whole support roller 5 terminates.
Spiral or step-by-step movement built-up welding can be used, it is possible to individual pen boxing, the welding of axial straight line or spot welding filling-up hole during built-up welding；Root
Setting welding route according to welding process requirement, the voltage when starting the arc, receipts arc, built-up welding, wire feed rate and receipts arc time, by welding gun control
Device processed controls each welding gun and is automatically performed weld deposit process.
The present invention disclosure satisfy that more than 20 tons, less than 80 tons, the heap repair welding of the diameter large-scale supporting roller less than 1800mm
Multiple requirement.
In the present invention, preferential U.S.'s Lincoln's welding gun of selecting, welding bead overlap joint is good, smooth, without slag inclusion pore；Can monofilament or double
The single arc built-up welding of silk, does not swing submerged arc overlay welding.The source of welding current uses U.S.'s Lincoln's AC/DC-1000A power supply, and supporting MAX19 welds control
Device processed and MAX29 wire-feed motor, (alternating current-direct current welding conversion can be can to use direct current, AC welding according to welding procedure actual requirement
Welding is carried out), exchange asymmetric waveform mode also can be used to weld.Welding wire can use Ф 2.4mm～Ф 5.0mm medicated core or reality
Cored welding wire.
The important technological parameters of welding mechanism is as follows:
Adaptation welding wire: medicated core or solid welding wire；
Welding wire specification:
Diameter of work:
Maximum length of workpiece :≤18000 (mm)；
Maximum workpiece weight :≤20 (T)；
Welding job electric current: 200～1000 (A)；
Welding job voltage: 20～44 (V)；
Main shaft working speed: 0.119～0.9r/min；
The welding gun amplitude of oscillation: 15～50/mm；
Welding gun wobble frequency: 10～50 times/min.
In order to be suitable for the built-up welding operation of different-diameter large-scale supporting roller, roller support means uses adjustable Anti-moving turning rolls
8, support roller 5 one side shaft journal and be installed on main spindle box 2 side by heavy chuck 3, driven by servomotor 1.Anti-moving
Turning rolls 8 preferentially uses fluid pressure type Anti-moving turning rolls, by 2 groups of symmetrically arranged roller racks, support, is used for supporting, lifting
And change the hydraulic system composition of carrying roller angle.In order to prevent because supporting the continuous one direction of roller 5 to rotate the axial float caused,
The 2 groups of carrying rollers front and back supported are respectively adopted the regulation of lever type hydraulic holding mechanism, change roller rack angle by hydraulic cylinder lifting
Degree, 2 hydraulic cylinders are servo hydraulic cylinder, in addition to participating in regulation angle, it is also possible to examined by the laser displacement sensor of axle head
Exclusive signal and the feedback surveyed form closed-loop control system, regulate the lifting of 2 hydraulic cylinders, correct axial displacement in time, and it is repaiied
The degree of accuracy just supporting roller 5 axial float precision can reach < 1mm.
The main body of main spindle box 2 is steel construction cover body, and main spindle box 2 is mounted with huge revolving bearing 11 and heavy chuck
3 for supporting transmission and the location of roller.Be inlaid with large modulus gear ring 15 at huge revolving bearing 11 inner ring, by with servomotor
Meshed transmission gear on 1 output shaft realizes driving and stepless speed regulation.Huge revolving bearing 11 inner ring and heavy chuck 3 it
Between connect transmission by scalable Hooks coupling universal coupling 10, scalable Hooks coupling universal coupling 10 and huge revolving bearing 11 inner ring and heavy type
Flange joint is all passed through between chuck 3.
Main spindle box 2 can move vertically, and its jacking system is by slide block 16 and the door-shaped frame being located at main spindle box 2 both sides
The slide mechanism that guide rail on 12 liang of heel posts is constituted, and two leading screws 17 being symmetrically installed on the crossbeam of door-shaped frame 12
Collectively constituting with the spiral lifting mechanism of the composition of main spindle box 2 top screw, it is horizontal that lifting motor 14 is mounted in door-shaped frame 12
A Worm reduction motor on beam, running motor 13 is mounted in a cycloidal-pin wheel bottom main spindle box 2 and slows down electric
Machine.
It is connected with a pair hand-worked lift being fixed on gate-type heating mantles 6 support bottom main spindle box 2, at main spindle box 2
After position adjustment puts in place, manually main spindle box 2 is fixed by elevator from bottom, it is to avoid the screw being suspended on main spindle box 2 is subject to
Damage.
Support the large-scale mobile work platform 4 that roller built-up welding station is arranged over to move vertically along support roll axis, many
Head welding mechanism, wire feeder structure, flux delivery mechanism, solder flux machine for automatically recovering, welding gun water-cooling system, electrical control cabinet
All it is arranged on mobile work platform 4 with whole umbilical lines.Mobile work platform 4 can move integrally, convenient support
Roller 5 is installed, and uses large lifting equipment to use special hanger hoisting large-size to support roller 5.Being provided with on mobile work platform 4 can
Carrying out many bond pads mechanism of three-axis moving, wherein welding gun travel mechanism is carried out certainly in welding gun inserts gate-type heating mantles 6
Dynamic built-up welding, and individually can extract welding gun at any time in stove out, change ignition tip, wire feed rolls and welding wire, and carry out the maintenance of equipment.
Other welding guns can normally work in the process, is 6～10min/ circles owing to supporting roller 5 autobiography speed, the ofest short duration welding gun
Safeguard not affect and support being normally carried out of roller built-up welding；Cold water is injected the water cooling tube in welding gun by water pump by welding gun water-cooling system
Road, heat is reduced by cold water, and Butt welding gun plays good thermolysis.It is additionally provided with infrared on the crossbeam of mobile work platform 4
Scanner 7 is for being monitored support roller 5 heating-up temperature.
Preheating and interlayer heating for whole support roller 5 are completed by faradism heater 27, use red
Outer scanner 7 detects the temperature supporting roller in real time, and the temperature that can scan body of roll each point continuously draws out temperature curve and colour
Thermograph.Arbitrarily it is divided into three sectors by supporting roller 5 body of roll and then monitors the temperature in these three region respectively, when detecting
When some region of temperature is less than setting value 400 DEG C, the faradism heater 27 automatically starting this region heats, until
Till temperature is up to standard.Whole process use PID close-loop control mode, intelligentized by temperature control in the reasonable scope.
In whole built-up welding work process, by advance the bead-welding technology parameter supporting roller 5 being carried out by control system
Setting, can realize the Automated condtrol of overall process, operator only need to control Indoor Video real-time parameter, and can pass through gate-type
Viewing window 30 on heating mantles 6 observes the welding situation within cover body.Therefore automaticity is high, greatly reduce operator
Labor intensity, optimize working environment, it is achieved that it is the most errorless that production process controls, also substantially increase and support the repairing of roller
Compound body amount and efficiency.
The above, the only present invention preferably detailed description of the invention, but protection scope of the present invention is not limited thereto,
Any those familiar with the art in the technical scope that the invention discloses, according to technical scheme and
Inventive concept equivalent or change in addition, all should contain within protection scope of the present invention.
Claims (10)
1. a large-scale supporting roller built-up welding work station, it is characterised in that include roller support means, roll driving apparatus, on-line heating
System, welding system and flux restoring system, support roller and supported location by roller support means, and can be in the driving of roll driving apparatus
Lower rotation；Described on-line heating system includes gate-type heating mantles, and gate-type heating mantles covers and supporting formation enclosing cover outside roller,
Cover body inwall is provided with heat-insulation layer and faradism heater, sets thermocouple in cover body, and covering on top sets welding gun entrance；Enter with welding gun
The gate-type heating mantles top of mouth correspondence position sets welding system and infrared scanner, and wherein the welding gun of welding system can move vertical
Stretch into after Dong in gate-type heating mantles cover body；Set flux restoring system bottom gate-type heating mantles, flux restoring system include vibrosieve,
Flux restoring box, solder flux machine for automatically recovering and solder flux storage tank, set movable hearth furnace bottom baffle, movable hearth furnace bottom gate-type heating mantles
Bottom baffle makes to be formed bottom gate-type heating mantles welding slag dropping channel after moving；Vibrosieve is placed in the lower section of welding slag dropping channel, shakes
Setting flux restoring box below dynamic sieve screen cloth, flux restoring box connects solder flux storage tank by solder flux machine for automatically recovering.
A kind of large-scale supporting roller built-up welding work station the most according to claim 1, it is characterised in that described roller support means is
Anti-moving turning rolls, uses hydraulic pressure or Mechanical Driven.
A kind of large-scale supporting roller built-up welding work station the most according to claim 1, it is characterised in that described roll driving apparatus is
Main spindle box；Main spindle box is provided with servomotor and huge revolving bearing, the inner ring of huge revolving bearing inlay large modulus gear ring with
Meshed transmission gear on servo motor output shaft, the inner ring of huge revolving bearing is by scalable Hooks coupling universal coupling and heavy four
Dog chuck connects transmission, and heavy chuck is used for the support roller side roll neck that is installed.
A kind of large-scale supporting roller built-up welding work station the most according to claim 3, it is characterised in that described main spindle box can be vertical
Lifting and edge support roll axis direction and move；Being provided with door-shaped frame outside main spindle box, main spindle box both sides set slide block and door-shaped frame
Guide rail on column matches, and main spindle box top sets screw and matches with the leading screw on door-shaped frame crossbeam, by being arranged on door
The lifting motor of shape frame roof drives, and main spindle box can realize vertical lift；Running mechanism is set, at running motor bottom main spindle box
Driving under can along support roll axis direction move；Hand-worked lift is set, after rising put in place at main spindle box bottom main spindle box
It is locked.
A kind of large-scale supporting roller built-up welding work station the most according to claim 1, it is characterised in that described gate-type heating mantles by
Anterior cover body, middle part cover body, rear portion cover body, overhead gage, lower baffle plate and movable hearth furnace bottom baffle collectively constitute enclosed construction, in
Cover body two ends, portion respectively with anterior cover body and rear portion cover body detachably connected composition main cover body；Overhead gage and lower baffle plate are along level
Axis subdivision, forms baffle plate after combination；Movable hearth furnace bottom baffle is 2 pieces, along cover body axisymmetrical arrange, and can respectively along with
Cover body axis vertical direction moves；The main cover body both sides of gate-type heating mantles are respectively mounted several pulley, and pulley is driven by reducing motor
Dynamic, and gate-type heating mantles main cover body can be driven along the slide be arrangeding in parallel with gate-type heating mantles axis；Lower baffle plate and track
Being fixed on equipment base, overhead gage is detachably connected with lower baffle plate.
A kind of large-scale supporting roller built-up welding work station the most according to claim 5, it is characterised in that described middle part cover body is provided with
Different lengths specification, is respectively used to support the use when different size supports roller built-up welding.
A kind of large-scale supporting roller built-up welding work station the most according to claim 1, it is characterised in that in described gate-type heating mantles
Part is multiple thermal treatment zone, and each thermal treatment zone is respectively provided with faradism heater；Faradism heater is by resistor, iron staff
And power supply composition, the resistor in each thermal treatment zone connects up according to the star structure of three-phase alternating current；Iron staff is incubated through cover body
Layer is fixed on cover body, outside suit ceramic dustcoat；Resistor is connected by iron staff with external power source；The sensing of each thermal treatment zone
Electric heater unit controls respectively；Being respectively equipped with thermocouple in each thermal treatment zone, thermocouple, infrared scanner and faradism add hot charging
Putting and be connected with heating control system respectively, heating control system is single-chip microcomputer or PLC.
A kind of large-scale supporting roller built-up welding work station the most according to claim 1, it is characterised in that described welding system includes
Array may move welding mechanism, and often the removable welding mechanism of group is by welding tractor, welding gun, welding gun moving apparatus, welding gun water-cooled
Device, welding wire conveying device, flux transport equipment form, and each assembly welding rifle connects welding gun controller respectively.
The operational approach of a kind of large-scale supporting roller built-up welding work station the most according to claim 1, it is characterised in that include as
Lower step:
1) roller support means is located in the middle of gate-type heating mantles track, near main spindle box side；Large-scale supporting roller is lifted on roller prop up
On support arrangement, adjust carrying roller height and angle makes support roll shaft edema with the heart involved put down；Adjust headstock so that it is on heavy four paws card
Dish is concentric with support roller, supports roller one end roll neck by heavy chuck fixing connection, and the servomotor on main spindle box can drive
The dynamic roller that supports rotates；
2) according to the specification of support roller, select the length of cover body in the middle part of gate-type heating mantles, after installing main cover body, start main cover body
The reducing motor of both sides, moves to main cover body support above roller, and forms cover body together with overhead gage, lower baffle plate；Cover welding gun
Capping at entrance and viewing window, closes movable hearth furnace bottom baffle, makes gate-type heating mantles cover body be in closed state；
3) starting the faradism heater of each thermal treatment zone, preheat and interlayer heating supporting roller, firing rate sets
Being 8～12 DEG C/h, when cover body temperature is 400～500 DEG C, reach preheating standard, preheating completes；
4) during welding, handle each welding gun and stretch in gate-type heating mantles cover body from welding gun porch, support roller in main spindle box servo
Motor is rotated by, and velocity of rotation is 6～10min/ circles；During welding, many welding guns can simultaneously or independently work, every welding gun
Built-up welding is carried out, until it reaches repair till requiring in respective region；Movable hearth furnace bottom baffle is opened by welding simultaneously, starts weldering
Agent recovery system, the residue produced in welding process falls in vibrosieve naturally, and granule is little and uniform unburned solder flux logical
Enter after crossing vibrating screen mesh in flux restoring box, under the suction function of solder flux machine for automatically recovering, enter solder flux by pipeline store up
Batch can；When needing the solder flux in use solder flux storage tank, air compressor starts, and utilizes malleation by returning in solder flux storage tank
Receiving in the welding flux box that solder flux injects in welding gun, the solder flux in welding flux box can be automatically injected in welding gun, it is achieved solder flux again with；
5), during built-up welding, use infrared scanner to detect in real time supporting roller body of roll temperature, and scan body of roll each point continuously
Temperature draws temperature curve and colored thermograph；Arbitrarily it is divided into 3 sectors by supporting roller and then controls the temperature in 3 regions
Degree, when the temperature detected is less than setting value 400 DEG C, the faradism heater of corresponding region is actuated for heating automatically,
Till temperature is up to standard；Whole process uses PID close-loop control mode to carry out intelligent temperature control, until welding terminates；
6) carrying out slow cooling for the first time after welding job completes, use the speed as programming rate to carry out slow cooling, slow cooling starts
The front gate-type heating mantles that removed by welding gun, gate-type heating mantles cover body recloses；By using PID closed loop control, control in cover body
Cooling rate；
7), after slow cooling terminates for the first time, again heat, to eliminate in welding process new resurfacing welding material with original supporting roller
Stress between material, is allowed to more preferably merge by high-temperature process；Programming rate is 8～12 DEG C/h, when cover body temperature reaches
Stop heating when 550～580 DEG C, be incubated 15～20 hours；
8) slow cooling for the second time uses the mode as during slow cooling for the first time, until during case temperature≤50 DEG C, slow cooling for the second time
Process terminates, and now supports roll temperature close to room temperature；
9) close on-line heating system, remove both sides overhead gage, gate-type heating mantles main cover body is removed from supporting roller top, whole
The Bead weld repair process supporting roller terminates.
The operational approach of a kind of large-scale supporting roller built-up welding work station the most according to claim 9, it is characterised in that built-up welding
Time can use spiral or step-by-step movement built-up welding, it is possible to individual pen boxing, the welding of axial straight line or spot welding filling-up hole；Want according to welding procedure
Ask setting welding route, the voltage when starting the arc, receipts arc, built-up welding, wire feed rate and receipts arc time, welding gun controller control each weldering
Rifle is automatically performed weld deposit process.
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| CN201610696123.2A CN106141375B (en) | 2016-08-19 | 2016-08-19 | A kind of operating method of large-scale supporting roller built-up welding work station |
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| CN107378198A (en) * | 2017-09-01 | 2017-11-24 | 盐城市荣翔机械科技有限公司 | A kind of automatic wear resistance sheetpile welding machine |
| CN110702876A (en) * | 2019-09-19 | 2020-01-17 | 徐州江恒能源科技有限公司 | System for testing whole process of gas-water migration of rock-soil mass under deep multi-field coupling effect |
| CN111730247A (en) * | 2020-06-22 | 2020-10-02 | 河北西柏坡发电有限责任公司 | Auxiliary device for welding repair of spindle of rotary machine |
| CN112464528A (en) * | 2020-11-10 | 2021-03-09 | 中国核动力研究设计院 | Method for measuring residual stress on inner surface and inside of welded pipeline |
| WO2021248653A1 (en) * | 2020-06-10 | 2021-12-16 | 南京英尼格玛工业自动化技术有限公司 | Transfer-type double-robot electric arc 3d printing workstation for high-speed rail sleeper beam process hole and working method thereof |
| CN113798711A (en) * | 2021-09-01 | 2021-12-17 | 河北新兴铸管有限公司 | Pipe die inner wall build-up welding system |
| CN113927206A (en) * | 2021-11-30 | 2022-01-14 | 武汉钢铁有限公司 | High-temperature wear resistant surfacing material for pinch roll and surfacing method thereof |
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| CN110702876A (en) * | 2019-09-19 | 2020-01-17 | 徐州江恒能源科技有限公司 | System for testing whole process of gas-water migration of rock-soil mass under deep multi-field coupling effect |
| WO2021248653A1 (en) * | 2020-06-10 | 2021-12-16 | 南京英尼格玛工业自动化技术有限公司 | Transfer-type double-robot electric arc 3d printing workstation for high-speed rail sleeper beam process hole and working method thereof |
| CN111730247A (en) * | 2020-06-22 | 2020-10-02 | 河北西柏坡发电有限责任公司 | Auxiliary device for welding repair of spindle of rotary machine |
| CN112464528A (en) * | 2020-11-10 | 2021-03-09 | 中国核动力研究设计院 | Method for measuring residual stress on inner surface and inside of welded pipeline |
| CN112464528B (en) * | 2020-11-10 | 2022-02-11 | 中国核动力研究设计院 | Method for measuring residual stress on inner surface and inside of welded pipeline |
| CN113798711A (en) * | 2021-09-01 | 2021-12-17 | 河北新兴铸管有限公司 | Pipe die inner wall build-up welding system |
| CN113927206A (en) * | 2021-11-30 | 2022-01-14 | 武汉钢铁有限公司 | High-temperature wear resistant surfacing material for pinch roll and surfacing method thereof |
| CN114393276A (en) * | 2022-01-28 | 2022-04-26 | 安徽马钢设备检修有限公司 | High-speed rail axle-shaped anvil surface strengthening surfacing welding process |
| CN114393276B (en) * | 2022-01-28 | 2023-09-01 | 安徽马钢设备检修有限公司 | High-speed railway axle type anvil surface strengthening surfacing process |
| CN117655582A (en) * | 2023-12-29 | 2024-03-08 | 安徽恒意硬面工程股份有限公司 | Infinite chilled cast iron substrate surfacing welding wire and surface repairing process |
| CN117655582B (en) * | 2023-12-29 | 2024-08-02 | 安徽恒意硬面工程股份有限公司 | Infinite chilled cast iron substrate surfacing welding wire and surface repairing process |
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