CN106141375B - A kind of operating method of large-scale supporting roller built-up welding work station - Google Patents
A kind of operating method of large-scale supporting roller built-up welding work station Download PDFInfo
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- CN106141375B CN106141375B CN201610696123.2A CN201610696123A CN106141375B CN 106141375 B CN106141375 B CN 106141375B CN 201610696123 A CN201610696123 A CN 201610696123A CN 106141375 B CN106141375 B CN 106141375B
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- heating mantles
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Classifications
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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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- 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 operating methods of large-scale supporting roller built-up welding work station, large-scale supporting roller built-up welding work station includes roller support device, roll driving apparatus, on-line heating system, welding system and flux restoring system, support roller is positioned by roller support device, and being rotated by roll driving apparatus；The gate-type heating mantles of on-line heating system, which are covered in outside support roller, forms enclosing cover, and cover body inner wall is equipped with insulating layer and induction electric heater unit, and welding gun can be stretched into after vertically moving in gate-type heating mantles cover body；Gate-type heating mantles bottom sets flux restoring system.In the present invention, support roller is heated and is kept the temperature in enclosing cover, and the welding simultaneously of multigroup welding mechanism simultaneously can recycle solder flux automatically, can realize the continuous process such as online preheating, welding, heat preservation and the temper of large-scale supporting roller；Easy to operate, high degree of automation, temperature control are accurate, are conducive to the surfacing quality for improving support 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 more particularly to a kind of large-scale supporting roller built-up welding work stations
Operating method.
Background technology
As present-day mill is to enlargement, high speed, automation direction development, the requirement to support roller is also increasingly
It is high.Support roller is one of the important component on each production line in actual production, and each heavy steel rolling mill will consume every year
A large amount of base parts.In order to reduce production cost, extend the service life of support roller, the mode of generally use roll surface built-up welding is to branch
Support roller is repaired so that it can be reused.
For the prior art, the Bead weld repair work difficulty of large-scale supporting roller is larger, and Major Difficulties are support roller
On-line heating problem, due to being difficult to realize closed heating, the aerial mode of heating of exposure makes it radiate quickly, it is difficult to
Reach welding temperature, so that support roller is shown that stress becomes larger in normal temperature welding below, support roller is easy out in welding process
Existing slight crack, it is very low to be welded into power.
Invention content
The present invention provides a kind of operating methods of large-scale supporting roller built-up welding work station, are supported by adjustable support roller
And drive system, support roller are heated and are kept the temperature in enclosing cover, the welding simultaneously of multigroup welding mechanism simultaneously can recycle solder flux automatically,
Realize the continuous process such as online preheating, welding, heat preservation and the temper of large-scale supporting roller；Easy to operate, automation journey
Degree is high, temperature control is accurate, is conducive to the surfacing quality for improving support roller, improves remediation efficiency, filled up the sky of this technology
In vain.
In order to achieve the above object, the present invention is realized using following technical scheme：
A kind of large-scale supporting roller built-up welding work station, including roller support device, roll driving apparatus, on-line heating system, welding
System and flux restoring system, support roller are positioned by roller support device, and being rotated by roll driving apparatus；Institute
It includes gate-type heating mantles to state on-line heating system, and gate-type heating mantles, which are covered in outside support roller, forms closed cover body, and gate-type adds
Hot cover cover body inner wall is equipped with insulating layer and induction electric heater unit, and thermocouple, gate-type heating mantles cover are set in gate-type heating mantles cover body
Welding gun entrance is set at the top of body；Welding system and infrared scanner are set with the gate-type heating mantles top of welding gun entrance corresponding position,
The welding gun of middle welding system can be stretched into after vertically moving in gate-type heating mantles cover body；Gate-type heating mantles bottom sets flux restoring system
System, flux restoring system includes vibrating screen, flux restoring box, solder flux machine for automatically recovering and solder flux storage tank, gate-type heating mantles bottom
Portion sets movable hearth furnace bottom baffle, so that gate-type heating mantles bottom is formed welding slag dropping channel after the movement of movable hearth furnace bottom baffle；Vibration
Sieve is placed in the lower section of welding slag dropping channel, sets flux restoring box below vibrating screen mesh, flux restoring box is returned automatically by solder flux
Receipts machine connects solder flux storage tank.
The roller support device is Anti-moving turning rolls, using hydraulic pressure or Mechanical Driven.
The roll driving apparatus is spindle box；Spindle box is equipped with servo motor and huge revolving bearing, huge revolving axis
The inner ring held inlays large modulus gear ring and the gear engaged transmission on servo motor output shaft, and the inner ring of huge revolving bearing passes through
Scalable Hooks coupling universal coupling connect transmission with heavy chuck, and heavy chuck is for the support roller side roll neck that is loaded.
The spindle box can be vertically moved up or down and be moved along support roller axis direction；Door-shaped frame is equipped on the outside of spindle box, it is main
Axle box both sides set sliding block and are matched with the guide rail on door-shaped frame column, are set at the top of spindle box on screw and door-shaped frame crossbeam
Leading screw matches, and is driven by the lifting motor at the top of door-shaped frame, and spindle box can realize vertical lift；Spindle box bottom
Portion sets running mechanism, can be moved along support roller axis direction under the driving of running motor；Spindle box bottom sets hand-worked lift,
For being locked afterwards in place in spindle box rise.
The gate-type heating mantles are by front cover body, middle part cover body, rear portion cover body, overhead gage, lower baffle plate and movable hearth furnace bottom
Baffle collectively constitutes enclosed construction, and middle part cover body both ends are led with front cover body and the detachably connected composition of rear portion cover body respectively
Cover body；Overhead gage forms baffle with lower baffle plate after horizontal median axis subdivision, combination；Movable hearth furnace bottom baffle is 2 pieces, along gate-type
Heating mantles cover body axisymmetrical is arranged, and can be moved respectively with gate-type heating mantles cover body axis vertical direction on edge；Gate-type heating mantles
Main cover body both sides several pulleys are installed respectively, pulley is driven by decelerating motor, and can drive gate-type heating mantles main cover bodies along with
The track sliding disposed in parallel of gate-type heating mantles axis；Lower baffle plate is fixed on track on equipment base, overhead gage and lower baffle plate
It is detachably connected.
The middle part cover body is equipped with different lengths specification, is respectively used to match when different size support roller built-up welding.
It is divided into multiple heating zones inside the gate-type heating mantles, induction electric heater unit is respectively set in each heating zone；Sense
Answer electric heater unit to be made of resistance band, iron staff and power supply, the resistance band in each heating zone according to three-phase alternating current star
Structural wiring；Iron staff is fixed on across insulating layer on gate-type heating mantles cover body, outside suit ceramic dustcoat；Resistance band and external electrical
Source is connected by iron staff；The induction electric heater unit of each heating zone controls respectively；It is respectively equipped with thermocouple in each heating zone,
Thermocouple, infrared scanner and induction electric heater unit are connect with heating control system respectively, and heating control system is microcontroller
Or PLC.
The welding system includes that array moves welding mechanism, and every group of removable welding mechanism is by welding tractor, weldering
Rifle, welding gun moving apparatus, welding gun water cooling plant, welding wire conveying device, flux transport equipment composition, each group welding gun are separately connected weldering
Gun controller.
A kind of operating method of large-scale supporting roller built-up welding work station, includes the following steps:
1) Anti-moving idler wheel is erected among gate-type heating mantles track, close to spindle box side；Large-scale supporting roller is lifted
Keep support roller axle center horizontal on Anti-moving turning rolls, adjusting carrying roller height and angle；Headstock is adjusted, weight thereon is made
Type chuck and support roller are concentric, and support roller one end roll neck, the servo on spindle box are fixedly connected with by heavy chuck
Motor can drive support roller to rotate；
2) according to the specification of support roller, the length of cover body in the middle part of gate-type heating mantles is selected, after installing main cover body, starts master
Main cover body is moved to above support roller, and forms gate-type heating mantles together with overhead gage, lower baffle plate by the decelerating motor of cover body both sides
Cover body；The capping at welding gun entrance and viewing window is covered, movable hearth furnace bottom baffle is closed, gate-type heating mantles cover body is made to be in closing
State；
3) the induction electric heater unit for starting each heating zone carries out preheating to support roller and interlayer heats, heating speed
It is set as 8~12 DEG C/h, when gate-type heating mantles cover body temperature is 400~500 DEG C, reaches preheating standard, preheating is completed；
4) it when welding, manipulates each welding gun and is stretched into gate-type heating mantles cover body from welding gun inlet, support roller is in spindle box
Servo motor is rotated by, and velocity of rotation is enclosed for 6~10min/；More welding guns can simultaneously or independently work when welding, every
Welding gun carries out built-up welding in respective region, until reaching reparation and requiring；Welding simultaneously opens movable hearth furnace bottom baffle, opens
Dynamic flux restoring system, the residue generated in welding process are fallen on vibrating screen naturally, and particle is small and uniform unburned freezes
Agent enters weldering under the suction function of solder flux machine for automatically recovering by entering in flux restoring box after vibrating screen mesh by pipeline
Agent storage tank；When needing to use the solder flux in solder flux storage tank, air compressor starts, will be in solder flux storage tank using positive pressure
Recycling solder flux injection welding gun in welding flux box in, the solder flux in welding flux box can be automatically injected in welding gun, realize solder flux again
It utilizes；
5) when built-up welding, support roller body of roll temperature is measured in real time using infrared scanner, and the continuous scanning body of roll is each
The temperature of point draws temperature curve and colored thermograph；Support roller is arbitrarily divided into 3 regions in 3 sectors and then control
Temperature, when the temperature detected is less than 400 DEG C of setting value, the induction electric heater unit of corresponding region be actuated for automatically plus
Heat, until temperature is up to standard；Whole process carries out intelligent temperature control using PID close-loop control modes, until welding terminates；
6) first time slow cooling is carried out after the completion of welding job, and slow cooling, slow cooling are carried out using speed same as heating speed
Welding gun is removed into gate-type heating mantles before starting, gate-type heating mantles cover body recloses；By using PID closed-loop controls, door is controlled
Cooling rate in formula heating mantles cover body；
7) after first time slow cooling, support roller is heated again, with eliminate in welding process new resurfacing welding material with
Stress between original material is allowed to more preferably merge by high-temperature process；Heating rate is 8~12 DEG C/h, when gate-type heating mantles
Cover body temperature stops heating when reaching 550~580 DEG C, keeps the temperature 15~20 hours；
8) same mode when second of slow cooling is used with first time slow cooling, until when case temperature≤50 DEG C, second
Annealing process terminates, at this time support roller temperature near room temperature；
9) on-line heating system is closed, the baffle of both sides is removed, gate-type heating mantles main cover body is removed from support roller top,
The Bead weld repair process of entire support roller terminates.
Spiral or step-by-step movement built-up welding can be used when built-up welding, it also can individual pen boxing, axial straight line welding or spot welding filling-up hole；Root
According to welding process requirement set welding route, the starting the arc, receive arc, built-up welding when voltage, wire feed rate and receive the arc time, by welding gun control
Device processed controls each welding gun and is automatically performed weld deposit process.
Compared with prior art, the beneficial effects of the invention are as follows：
1) supported by adjustable support roller and drive system, driven using high-power servo motor, support roller with
It is connected by scalable Hooks coupling universal coupling between spindle box, has staring torque big, speed-regulating range width, convenient for control, aligning is simple
The advantages that；Support roller is supported using adjustable Anti-moving turning rolls, avoid the occurrence of skiddings, throw switch and caused by welding deposition it is golden
Category is rewelded, and phenomena such as catching up with heap out-of-flatness influences surfacing quality, and stability of rotation when support roller built-up welding does not creep, do not throw switch, carrying energy
Power is big, rotating torque is small, can stepless time adjustment；
2) on-line heating and heat preservation are automatically controlled by PID regulator+two-way controllable module realization, and robot control system(RCS) can be to online
Heating, attemperator are monitored in real time and are adjusted, it is ensured that interlayer temperature and quality when roll welds；
3) built-up welding is set using the welding simultaneously of multigroup moveable welding mechanism, wherein necked part by CMT pulsed cold weldings
Standby to complete, high-power water-cooling welding gun can realize continuous built-up welding for a long time；Spiral or step-by-step movement built-up welding can be used in welding manner,
It 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, you can automatic adjustment, welding process continuous-stable provide solid for large-scale roller surfacing quality
Guarantee；
4) it can be achieved while the automatic conveying of multiple welding head solder flux, welding carry out Automatic sieve to solder flux and welding slag simultaneously
Divide and recycles；
5) using intelligent full-automatic control system, comprehensive effective automatic control is carried out to large-scale supporting roller built-up welding work station
System and automatic monitoring；Online preheating, welding, heat preservation and the temper technical process that can continuously realize large-scale supporting roller, from
Dynamicization degree is high, and integration is good；
6) have welding, driving, heating, flux delivery and reclaimer failure real-time detection alarming function, it is ensured that equipment
Operational safety is reliable and stable.
Description of the drawings
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 spindle box and portal frame of the present invention.
Fig. 4 is the rearview of Fig. 3.
Fig. 5 is the vertical view of Fig. 3.
Fig. 6 is the side view of Fig. 3.
Fig. 7 is the A-A sectional views in Fig. 1.
Fig. 8 is the structural schematic diagram of gate-type heating mantles of the present invention.
Fig. 9 is the main view sectional view 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. 4. mobile work platform of the heavy chuck of 2. spindle box of servo motor 3., 5. support roller 6.
7. infrared scanner of gate-type heating mantles, 8. Anti-moving turning rolls, 9. 10. scalable Hooks coupling universal coupling of track, 11. huge revolving
16. sliding block of bearing 12. door-shaped frame, 13. running motor, 14. lifting motor, 15. large modulus gear ring, 17. leading screw 18. can
Cover body 21. welding gun entrance in the rear portions cover body 20-3. in the middle part of mobile 19. fronts vibrating screen 20-1. cover body 20-2. of furnace bottom baffle
22. 25. decelerating motor of overhead gage 23. lower baffle plate, 24. pulley, 26. iron staff 27. incudes 28. thermocouple of electric heater unit
29. 32. wind turbine of heating zone 30. window viewport, 31. insulating layer
Specific implementation mode
The specific implementation mode of the present invention is described further below in conjunction with the accompanying drawings：
See be shown in Fig. 1-Fig. 2 a kind of large-scale supporting roller built-up welding work station of the present invention structural schematic diagram.The present invention
A kind of large-scale supporting roller built-up welding work station, including roller support device, roll driving apparatus, on-line heating system, welding system
With flux restoring system, support roller 5 is positioned by roller support device, and being rotated by roll driving apparatus；It is described
On-line heating system includes gate-type heating mantles 6, and gate-type heating mantles 6 are covered in 5 outside of support roller and form closed cover body, and gate-type adds
Hot cover cover body inner wall is equipped with insulating layer 31 and induction electric heater unit 27, sets thermocouple 28 in gate-type heating mantles cover body, gate-type adds
Hot cover covering on top sets welding gun entrance 21；Welding system and red is set with 6 top of gate-type heating mantles of 21 corresponding position of welding gun entrance
Outer scanner 7, the wherein welding gun of welding system can be stretched into after vertically moving in 6 cover body of gate-type heating mantles；6 bottom of gate-type heating mantles
Portion sets flux restoring system, and flux restoring system includes vibrating screen 19, flux restoring box, solder flux machine for automatically recovering and solder flux storing
Tank, 6 bottom of gate-type heating mantles set movable hearth furnace bottom baffle 18, and movable hearth furnace bottom baffle 18 makes 6 bottom of gate-type heating mantles after moving
Form welding slag dropping channel；Vibrating screen 19 is placed in the lower section of welding slag dropping channel, and flux restoring box is set below 19 sieve of vibrating screen,
Flux restoring box connects solder flux storage tank by solder flux machine for automatically recovering.
The roller support device is Anti-moving turning rolls 8, using hydraulic pressure or Mechanical Driven.(as shown in Figure 7)
As shown in figures 3 to 6, the roll driving apparatus is spindle box 2；Spindle box 2 is equipped with servo motor 1 and large-scale time
Shaft holds 11, and the inner ring of huge revolving bearing 11 inlays large modulus gear ring 15 and engages biography with the gear on 1 output shaft of servo motor
Dynamic, the inner ring of huge revolving bearing 11 connect transmission, heavy four paws by scalable Hooks coupling universal coupling 10 with heavy chuck 3
Chuck 3 is for the 5 side roll neck of support roller that is loaded.
The spindle box 2 can be vertically moved up or down and be moved along 5 axis direction of support roller；2 outside of spindle box is equipped with door-shaped frame
12,2 both sides of spindle box set sliding block 16 and are matched with the guide rail on 12 column of door-shaped frame, and 2 top of spindle box sets screw and door shape
Leading screw 17 on 12 crossbeam of frame matches, and is driven by the lifting motor 14 mounted on 12 top of door-shaped frame, spindle box 2 can
Realize vertical lift；2 bottom of spindle box sets running mechanism, can be moved along 5 axis direction of support roller under the driving of running motor 13
It is dynamic；2 bottom of spindle box sets hand-worked lift, for being locked afterwards in place in the rise of spindle box 2.
As Figure 8-Figure 10, the gate-type heating mantles 6 are by front 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, the middle part both ends cover body 20-2 difference
With front cover body 20-1 and the detachably connected composition main cover bodies of rear portion cover body 20-3；Overhead gage 22 is with lower baffle plate 23 along level
Axis subdivision forms baffle after combination；Movable hearth furnace bottom baffle 18 is 2 pieces, is arranged along gate-type heating mantles cover body axisymmetrical, and
It can be moved respectively with gate-type heating mantles cover body axis vertical direction on edge；Install respectively several in the main cover body both sides of gate-type heating mantles 6
Pulley 24, pulley 24 are driven by decelerating motor 25, and 6 main cover body of gate-type heating mantles can be driven along flat with 6 axis of gate-type heating mantles
The track 9 of row setting slides；Lower baffle plate 23 is fixed on track 9 on equipment base, and overhead gage 22 and lower baffle plate 23 are removably
Connection.
The middle part cover body 20-2 is equipped with different lengths specification, mating when being respectively used to different size 5 built-up welding of support roller to make
With.
As shown in figure 9, being divided into multiple heating zones 29 inside the gate-type heating mantles 6, sense is respectively set in each heating zone 29
Answer electric heater unit 27；Induction electric heater unit 27 is made of resistance band, iron staff 26 and power supply, the resistance in each heating zone 29
Band is connected up according to the star structure of three-phase alternating current；Iron staff 26 is fixed on across insulating layer 31 on gate-type heating mantles cover body, external
It is set with ceramic dustcoat；Resistance band is connected with external power supply by iron staff 26；The induction electric heater unit 27 of each heating zone 29 divides
It does not control；Thermocouple 28, thermocouple 28, infrared scanner 7 and induction electric heater unit 27 are respectively equipped in each heating zone 29
It is connect respectively with heating control system, heating control system is microcontroller or PLC.
The welding system includes that array moves welding mechanism, and every group of removable welding mechanism is by welding tractor, weldering
Rifle, welding gun moving apparatus, welding gun water cooling plant, welding wire conveying device, flux transport equipment composition, each group welding gun are separately connected weldering
Gun controller.
A kind of operating method of large-scale supporting roller built-up welding work station, includes the following steps:
1) Anti-moving idler wheel is erected among gate-type heating mantles track 9, close to 2 side of spindle box；Large-scale supporting roller 5 is hung
Keep 5 axle center of support roller horizontal loaded on carrying roller height and angle on Anti-moving turning rolls, is adjusted；2 position of spindle box is adjusted, is made thereon
Heavy chuck 3 and support roller 5 it is concentric, 5 one end roll neck of support roller, spindle box 2 are fixedly connected with by heavy chuck 3
On servo motor 1 can drive support roller 5 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,
Main cover body is moved to 5 top of support roller by the decelerating motor 25 for starting main cover body both sides, and together with overhead gage 22, lower baffle plate 23
Form gate-type heating mantles cover body；The capping at welding gun entrance 21 and viewing window 30 is covered, movable hearth furnace bottom baffle 18 is closed, makes door
Formula heating mantles cover body is in closed state；
3) the induction electric heater unit 27 for starting each heating zone 29 carries out preheating to support roller 5 and interlayer heats, heating
Speed is set as 8~12 DEG C/h, when cover body temperature is 400~500 DEG C, reaches preheating standard, preheating is completed；
4) it when welding, manipulates each welding gun and is stretched into from welding gun entrance 21 in 6 cover body of gate-type heating mantles, support roller 5 is in master
Axle box servo motor 1 is rotated by, and velocity of rotation is enclosed for 6~10min/；More welding guns can simultaneously or independently work when welding,
Every welding gun carries out built-up welding in respective region, until reaching reparation and requiring；Welding is simultaneously by movable hearth furnace bottom baffle 18
It opens, starts flux restoring system, the residue generated in welding process is fallen to naturally on vibrating screen 19, and particle is small and uniform
Unburned solder flux is passed through by entering in flux restoring box after 19 sieve of vibrating screen under the suction function of solder flux machine for automatically recovering
Pipeline enters solder flux storage tank；When needing to use the solder flux in solder flux storage tank, air compressor starts, and will be welded using positive pressure
In the welding flux box in recycling solder flux injection welding gun in agent storage tank, the solder flux in welding flux box can be automatically injected in welding gun, be realized
The utilization again of solder flux；
5) when built-up welding, 5 body of roll temperature of support roller is measured in real time using infrared scanner 7, and the continuous scanning body of roll
The temperature of each point draws temperature curve and colored thermograph；Support roller 5 is arbitrarily divided into 3 sectors and then controls 3 areas
The temperature in domain, when the temperature detected is less than 400 DEG C of setting value, the induction electric heater unit 27 of corresponding region is automatic start into
Row heating, until temperature is up to standard；Whole process carries out intelligent temperature control using PID close-loop control modes, until welding
Terminate；
6) first time slow cooling is carried out after the completion of welding job, and slow cooling, slow cooling are carried out using speed same as heating speed
Welding gun is removed into gate-type heating mantles 6 before starting, 6 cover body of gate-type heating mantles recloses；By using PID closed-loop controls, control
Cooling rate in gate-type heating mantles cover body；
7) after first time slow cooling, support roller 5 is heated again, with eliminate in welding process new resurfacing welding material with
Stress between original material is allowed to more preferably merge by high-temperature process；Heating rate is 8~12 DEG C/h, when gate-type heating mantles
Cover body temperature stops heating when reaching 550~580 DEG C, keeps the temperature 15~20 hours；
8) same mode when second of slow cooling is used with first time slow cooling, until when case temperature≤50 DEG C, second
Annealing process terminates, at this time 5 temperature near room temperature of support roller；
9) on-line heating system is closed, the baffle of both sides is removed, 6 main cover body of gate-type heating mantles is moved from 5 top of support roller
It opens, the Bead weld repair process of entire support roller 5 terminates.
Spiral or step-by-step movement built-up welding can be used when built-up welding, it also can individual pen boxing, axial straight line welding or spot welding filling-up hole；Root
According to welding process requirement set welding route, the starting the arc, receive arc, built-up welding when voltage, wire feed rate and receive the 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 20 tons or more, 80 tons hereinafter, diameter no more than 1800mm large-scale supporting roller heap repair welding
It is multiple to require.
Preferential to select U.S.'s Lincoln's welding gun in the present invention, welding bead overlap joint is good, smooth, without slag inclusion stomata；It 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 supplys, mating MAX19 welding control
Device and MAX29 wire-feed motor processed, can using direct current, AC welding, (alternating current-direct current welding conversion can be according to welding procedure actual requirement
Carried out in welding), exchange asymmetric waveform mode also can be used and weld.Ф 2.4mm~Ф 5.0mm medicine cores or reality can be used in welding wire
Cored welding wire.
The important technological parameters of welding mechanism are as follows：
Adapt to welding wire：Medicine core or solid welding wire；
Welding wire specification：2.4~φ of φ 5.6 (mm)；
Diameter of work：170~φ of φ 500 (mm)；
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 suitble to the built-up welding operation of different-diameter large-scale supporting roller, roller support device to use adjustable Anti-moving turning rolls
8,5 one side shaft journal of support roller is loaded on 2 side of spindle box by heavy chuck 3, is driven by servo motor 1.Anti-moving
Turning rolls 8 preferentially uses fluid pressure type Anti-moving turning rolls, by 2 groups of symmetrically arranged roller racks, engine base, is used to support, lifts
And change the hydraulic system composition of carrying roller angle.In order to prevent because of axial float caused by the rotation of 5 continuous one direction of support roller,
The adjusting of lever type hydraulic holding mechanism is respectively adopted in 2 groups of carrying rollers of front and back support, is lifted by hydraulic cylinder and changes roller rack angle
Degree, 2 hydraulic cylinders are servo hydraulic cylinder, are outside one's consideration, can also be examined by the laser displacement sensor of shaft end except adjustment angle is participated in
The exclusive signal and feedback of survey form closed-loop control system, and lifting, correcting axial displacement in time for 2 hydraulic cylinders of adjusting is repaiied
The accuracy of 5 axial float precision of positive support roller can reach<1mm.
The main body of spindle box 2 is steel construction cover body, and huge revolving bearing 11 and heavy chuck are mounted on spindle box 2
3 are used to support the transmission and positioning of roller.Be inlaid with large modulus gear ring 15 in 11 inner ring of huge revolving bearing, by with servo motor
Gear engaged transmission on 1 output shaft realizes driving and stepless speed regulation.11 inner ring of huge revolving bearing and heavy chuck 3 it
Between pass through the connection transmission of scalable Hooks coupling universal coupling 10, scalable Hooks coupling universal coupling 10 and 11 inner ring of huge revolving bearing and heavy type
Pass through flanged joint between chuck 3.
Spindle box 2 can be moved vertically, its jacking system is by being located at the sliding block 16 and door-shaped frame of 2 both sides of spindle box
The sliding equipment 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
It is collectively constituted with the spiral lifting mechanism of the composition of 2 top screw of spindle box, it is horizontal that lifting motor 14 is mounted in door-shaped frame 12
A Worm reduction motor on beam, running motor 13 are mounted in the cycloidal-pin wheel deceleration electricity of 2 bottom of spindle box
Machine.
2 bottom of spindle box is connected with a pair of of the hand-worked lift being fixed on 6 engine base of gate-type heating mantles, in spindle box 2
After position is adjusted in place, spindle box 2 is fixed from bottom by hand-worked lift, avoid the screw being suspended on spindle box 2 by
Damage.
Being equipped with above support roller built-up welding station can be more along the large-scale mobile work platform 4 of support roll axis vertical movement
Head welding mechanism, wire feeder structure, flux delivery mechanism, solder flux machine for automatically recovering, welding gun water-cooling system, electrical control cabinet
With whole tube cables all on mobile work platform 4.Mobile work platform 4 can move integrally, and facilitate support
Roller 5 is installed, and special hanger hoisting large-size support roller 5 is used using large lifting equipment.Being equipped on mobile work platform 4 can
Multigroup welding mechanism of progress three-axis moving, wherein welding gun mobile mechanism are used to welding gun being inserted into gate-type heating mantles 6 and carry out certainly
Dynamic built-up welding, and can individually extract welding gun out out of stove at any time, ignition tip, wire feed rolls and welding wire are replaced, and carry out the repair of equipment.
Other welding guns can work normally in the process, since 5 autobiography speed of support roller is enclosed for 6~10min/, of short duration welding gun
Maintenance does not influence being normally carried out for support 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, cold water reduce heat, and Butt welding gun plays good cooling effect.It is additionally provided on the crossbeam of mobile work platform 4 infrared
Scanner 7 is for being monitored 5 heating temperature of support roller.
Preheating and interlayer heating for entire support roller 5 are completed by incuding electric heater unit 27, and use is red
Outer scanner 7 detects the temperature of support roller in real time, can draw out temperature curve and colour with the temperature of continuous scanning body of roll each point
Thermograph.5 body of roll of support roller is arbitrarily divided into three sectors and then monitors the temperature in these three regions respectively, when detecting
When some region of temperature is less than 400 DEG C of setting value, the induction electric heater unit 27 for starting the region automatically is heated, until
Until temperature is up to standard.Whole process uses PID close-loop control modes, intelligentized to control temperature in the reasonable scope.
In the entire built-up welding course of work, by the way that the bead-welding technology parameter of support roller 5 is carried out by control system in advance
The automation control, it can be achieved that overall process is set, operating personnel only need to be in control Indoor Video real-time parameter, and can pass through gate-type
Viewing window 30 on heating mantles 6 observes the welding situation inside cover body.Therefore high degree of automation, greatly reduce operating personnel
Labor intensity, optimize operating environment, realize production process control it is accurate errorless, also substantially increase repairing for support roller
Compound body amount and efficiency.
The foregoing is only a preferred embodiment of the present invention, but scope of protection of the present invention is not limited thereto,
Any one skilled in the art in the technical scope disclosed by the present invention, according to the technique and scheme of the present invention and its
Inventive concept is subject to equivalent substitution or change, should be covered by the protection scope of the present invention.
Claims (8)
1. a kind of operating method of large-scale supporting roller built-up welding work station, which is characterized in that the large-scale supporting roller built-up welding work station
It is supported by roller including roller support device, roll driving apparatus, on-line heating system, welding system and flux restoring system, support roller
Device support positioning, and being rotated by roll driving apparatus；The on-line heating system includes gate-type heating mantles, gate-type
Heating mantles, which are covered in outside support roller, forms closed cover body, and gate-type heating mantles cover body inner wall is equipped with insulating layer and induction electrical heating
Device sets thermocouple in gate-type heating mantles cover body, and gate-type heating mantles covering on top sets welding gun entrance；With welding gun entrance corresponding position
Gate-type heating mantles top set welding system and infrared scanner, the wherein welding gun of welding system can stretch into door after vertically moving
In formula heating mantles cover body；Gate-type heating mantles bottom sets flux restoring system, and flux restoring system includes vibrating screen, flux restoring
Box, solder flux machine for automatically recovering and solder flux storage tank, gate-type heating mantles bottom set movable hearth furnace bottom baffle, and movable hearth furnace bottom baffle moves
Gate-type heating mantles bottom is set to form welding slag dropping channel after dynamic；Vibrating screen 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；
The roller support device is Anti-moving turning rolls；The roll driving apparatus is spindle box；Spindle box is equipped with servo motor
With huge revolving bearing；The gate-type heating mantles are by front cover body, middle part cover body, rear portion cover body, overhead gage, lower baffle plate and removable
Dynamic furnace bottom baffle collectively constitutes enclosed construction, and middle part cover body both ends are detachably connected with front cover body and rear portion cover body respectively
Form main cover body；Overhead gage forms baffle with lower baffle plate after horizontal median axis subdivision, combination；The middle part cover body is equipped with a variety of
Length specification is respectively used to match when different size support roller built-up welding；It is divided into multiple heating inside the gate-type heating mantles
Induction electric heater unit is respectively set in area, each heating zone；
The operating method of the large-scale supporting roller built-up welding work station, includes the following steps:
1）Anti-moving idler wheel is erected among gate-type heating mantles track, close to spindle box side；Large-scale supporting roller is lifted on anti-
On play turning rolls, adjusting the carrying roller height of Anti-moving turning rolls and angle keeps support roller axle center horizontal；Headstock is adjusted,
Keep heavy chuck thereon and support roller concentric, support roller one end roll neck, main shaft are fixedly connected with by heavy chuck
Servo motor on case can drive support roller to rotate；
2）According to the specification of support roller, the length of cover body in the middle part of gate-type heating mantles is selected, after installing main cover body, starts main cover body
Main cover body is moved to above support roller, and forms gate-type heating mantles cover together with overhead gage, lower baffle plate by the decelerating motor of both sides
Body；The capping at welding gun entrance and viewing window is covered, movable hearth furnace bottom baffle is closed, gate-type heating mantles cover body is made to be in closed
State；
3）The induction electric heater unit for starting each heating zone carries out preheating to support roller and interlayer heats, heating speed setting
Reach preheating standard when gate-type heating mantles cover body temperature is 400~500 DEG C for 8~12 DEG C/h, preheating is completed；
4）When welding, manipulates each welding gun and stretched into gate-type heating mantles cover body from welding gun inlet, support roller is in spindle box servo
Motor is rotated by, and velocity of rotation is enclosed for 6~10min/；More welding guns can simultaneously or independently work when welding, every welding gun
Built-up welding is carried out in respective region, until reaching reparation and requiring；Welding simultaneously opens movable hearth furnace bottom baffle, starts weldering
Agent recovery system, the residue generated in welding process are fallen on vibrating screen naturally, and particle is small and uniform unburned solder flux is logical
Enter in flux restoring box after crossing vibrating screen mesh, solder flux storage is entered by pipeline under the suction function of solder flux machine for automatically recovering
Batch can；When needing using solder flux in solder flux storage tank, air compressor starts, using positive pressure by returning in solder flux storage tank
It receives in the welding flux box in solder flux injection welding gun, the solder flux in welding flux box can be automatically injected in welding gun, realize the utilization again of solder flux；
5）When built-up welding, support roller body of roll temperature is measured in real time using infrared scanner, and continuous scanning body of roll each point
Temperature draws temperature curve and colored thermograph；Support roller is arbitrarily divided into 3 sectors and then controls the temperature in 3 regions
Degree, when the temperature detected is less than 400 DEG C of setting value, the induction electric heater unit of corresponding region is actuated for heating automatically,
Until temperature is up to standard；Whole process carries out intelligent temperature control using PID close-loop control modes, until welding terminates；
6）First time slow cooling is carried out after the completion of welding job, slow cooling is carried out using speed same as heating speed, slow cooling starts
Preceding that welding gun is removed gate-type heating mantles, gate-type heating mantles cover body recloses；By using PID closed-loop controls, control gate-type adds
Cooling rate in hot cover cover body；
7）After first time slow cooling, support roller is heated again, with eliminate in welding process new resurfacing welding material with it is original
Stress between material is allowed to more preferably merge by high-temperature process；Heating rate is 8~12 DEG C/h, when gate-type heating mantles cover body
Interior temperature stops heating when reaching 550~580 DEG C, keeps the temperature 15~20 hours；
8）Second of slow cooling same mode when using with first time slow cooling, until when case temperature≤50 DEG C, second of slow cooling
Process terminates, at this time support roller temperature near room temperature；
9）On-line heating system is closed, the baffle of both sides is removed, gate-type heating mantles main cover body is removed from support roller top, entirely
The Bead weld repair process of support roller terminates.
2. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that described anti-
Play turning rolls uses hydraulic-driven.
3. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that described big
The inner ring of type floating bearing inlays large modulus gear ring and the gear engaged transmission on servo motor output shaft, huge revolving bearing
Inner ring connect transmission by scalable Hooks coupling universal coupling with heavy chuck, and heavy chuck is for the support roller side that is loaded
Roll neck.
4. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that the master
Axle box can be vertically moved up or down and be moved along support roller axis direction；Door-shaped frame is equipped on the outside of spindle box, spindle box both sides set sliding block
It is matched with the guide rail on door-shaped frame column, set screw at the top of spindle box matches with the leading screw on door-shaped frame crossbeam, leads to
The lifting motor driving at the top of door-shaped frame is crossed, spindle box can realize vertical lift；Spindle box bottom sets running mechanism,
It can be moved along support roller axis direction under the driving of running motor；Spindle box bottom sets hand-worked lift, in spindle box
Rise is locked afterwards in place.
5. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that it is described can
Mobile furnace bottom baffle is 2 pieces, is arranged along gate-type heating mantles cover body axisymmetrical, and can respectively along and gate-type heating mantles cover body axis
Vertical direction moves；Several pulleys are installed in the main cover body both sides of gate-type heating mantles respectively, and pulley is driven by decelerating motor, and can band
The main cover body of dynamic gate-type heating mantles is slided along with gate-type heating mantles axis track disposed in parallel；Lower baffle plate is fixed on track and sets
On standby pedestal, overhead gage is detachably connected with lower baffle plate.
6. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that the sense
Answer electric heater unit to be made of resistance band, iron staff and power supply, the resistance band in each heating zone according to three-phase alternating current star
Structural wiring；Iron staff is fixed on across insulating layer on gate-type heating mantles cover body, outside suit ceramic dustcoat；Resistance band and external electrical
Source is connected by iron staff；The induction electric heater unit of each heating zone controls respectively；It is respectively equipped with thermocouple in each heating zone,
Thermocouple, infrared scanner and induction electric heater unit are connect with heating control system respectively, and heating control system is microcontroller
Or PLC.
7. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that the weldering
Welding system includes that array moves welding mechanism, and every group of removable welding mechanism is by welding tractor, welding gun, welding gun movement dress
It sets, welding gun water cooling plant, welding wire conveying device, flux transport equipment composition, each group welding gun is separately connected welding gun controller.
8. a kind of operating method of large-scale supporting roller built-up welding work station according to claim 1, which is characterized in that when built-up welding
Using spiral or step-by-step movement built-up welding or individual pen boxing, axial straight line welding, spot welding filling-up hole；It is set according to welding process requirement
Weld route, the starting the arc, voltage when receiving arc, built-up welding and are received the arc time wire feed rate, and it is automatic to control each welding gun by welding gun controller
Complete weld deposit process.
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