CN106738937B - 一种pe管的摩擦热熔装置及方法 - Google Patents

一种pe管的摩擦热熔装置及方法 Download PDF

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CN106738937B
CN106738937B CN201710059938.4A CN201710059938A CN106738937B CN 106738937 B CN106738937 B CN 106738937B CN 201710059938 A CN201710059938 A CN 201710059938A CN 106738937 B CN106738937 B CN 106738937B
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welded
pipe
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陈英红
杨剑赟
丛成龙
王磊
戚政武
矫庆泽
汤景升
庞慕妮
张俊豪
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Zhuhai Anyes Technology Co ltd
Beijing Institute of Technology Zhuhai
Guangdong Inspection and Research Institute of Special Equipment Zhuhai Inspection Institute
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Beijing Institute of Technology Zhuhai
Guangdong Inspection and Research Institute of Special Equipment Zhuhai Inspection Institute
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0681—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding created by a tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5221—Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B29C66/0222—Mechanical pre-treatments, e.g. reshaping without removal of material, e.g. cleaning by air blowing or using brushes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2023/00—Tubular articles
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A20/00—Water conservation; Efficient water supply; Efficient water use
    • Y02A20/20—Controlling water pollution; Waste water treatment

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Abstract

本发明公开了一种PE管的摩擦热熔装置，包括支架和安装在支架上的驱动电机，驱动电机的输出轴连接主动轮，从动轮的中心安装有齿轮轴，齿轮轴的两端均啮合有固定盘，固定盘外侧固定安装有摩擦片，从动轮两侧均设有至少两个套筒，套筒内套设有压簧，机架位于两块摩擦片外侧分别固定安装有两块产热盘，摩擦片与产热盘紧密接触，通过驱动电机带动摩擦片与产热盘摩擦生热。本发明还公开了一种PE管的摩擦热熔方法，利用摩擦热熔装置替换加热板，在两根待焊PE管中间引入产热盘并紧密接触，通过驱动电机高速旋转摩擦生热，以使待焊PE管件端面热熔并相互连接，摩擦热输入相同，可解决加热板的温度不均匀性、显示偏差、温度波动等问题。

Description

一种PE管的摩擦热熔装置及方法
技术领域
本发明涉及PE管热熔焊接工艺，尤其涉及一种PE管的摩擦热熔装置及方法。
背景技术
聚乙烯（PE）管道因其使用寿命长、耐腐性强、力学性能（弯曲性能）优良等优势，被广泛应用于城镇燃气管道工程中，其焊接质量的好坏与人民群众生命财产安全息息相关。
目前广泛使用的热熔焊机是专门用于连接聚乙烯（PE）管的焊接设备，具有施工成本少、操作简单、焊接质量较好的特点。目前常见的热熔焊机主要为液压控制型，其主要部件包括主机、加热板、铣刀、机架、夹具、油管和数据传输线等连接线。主机用于控制液压系统与夹具位移，全自动型热熔焊机的主机还监控焊接过程中各阶段的其他参数的运行；加热板用于给待焊PE管件端面提供热量并使之熔融，是热熔焊接过程中的关键部件，接头性能的好坏与焊接过程的温度、压力及加热时间有关，而加热温度和加热时间由加热板控制，压力由主机控制，因此主机与加热板的性能基本决定了热熔焊机的质量水平。
热熔焊机质量的好坏决定接头质量的优劣，但目前热熔焊机由于缺乏定期的检验维护，使用一段时间后各部件均会出现不同程度的问题，存在的问题主要集中于主机与加热板。部分焊机的加热板存在温度均匀性及显示偏差不能满足国家标准要求的问题，另一方面，由于国家标准没有明确规定加热板的温度稳定性要求与允许工作温度范围，部分焊机的加热板的温度波动较大，厂家设定的加热板温度与要求的偏差范围较宽，直接影响了对加热板温度的控制。除此之外，在整个工艺过程中，加热板的预热需要一定的时间，这在一定程度上影响了工程的效率。
发明内容
为了克服上述现有技术的不足，本发明提供了一种PE管的摩擦热熔装置及方法，能够使得待焊PE管件的端面温度均匀，而且节能、高效。
本发明解决其技术问题所采用的技术方案为：
一种PE管的摩擦热熔装置，包括支架和安装在支架上的驱动电机，所述驱动电机的输出轴连接主动轮，所述主动轮通过皮带连接从动轮，所述从动轮的中心安装有齿轮轴，所述齿轮轴的两端均啮合有固定盘，所述固定盘外侧固定安装有摩擦片，所述从动轮两侧均设有至少两个套筒，所述套筒内套设有压簧，所述压簧一端抵顶在从动轮上，另一端抵顶在固定盘上，所述支架位于两块摩擦片外侧分别固定安装有两块产热盘，所述摩擦片与产热盘紧密接触。
作为上述技术方案的改进，所述固定盘内侧开设有定位槽，所述压簧的另一端对应抵顶在定位槽内。
作为上述技术方案的改进，所述从动轮两侧均设有四个套筒。
一种PE管的摩擦热熔方法，该方法包括：
步骤一、首先清洁待焊PE管件表面的油污污染物或泥土污染物，装夹待焊PE管件，保证同轴度与圆度不超过公差范围，切削并修整管道端面，保证端面的平直以及轴线的垂直；
步骤二、将摩擦热熔装置固定于两根待焊PE管件之间，待焊PE管件的待焊端面与产热盘的外表面保持接触；
步骤三、通过对待焊PE管件施加较高的压力P1，使待焊PE管件的待焊端面与产热盘的外表面紧密接触，并保持压力P1不变，启动驱动电机，使主动轮、从动轮、齿轮轴、固定盘和摩擦片高速旋转，对产热盘摩擦产热，当待焊PE管件的塑料达到熔融状态，并开始向外侧流动时，降低压力至P2；
步骤四、当达到设定的摩擦时间后，待焊PE管件已具有一定的塑性层厚度，停止驱动电机并移出摩擦热熔装置；
步骤五、在顶锻压力P3的作用下，将两根待焊PE管件的待焊端面对接，并保持P3一定时间，使两根待焊PE管件紧密连接在一起。
本发明的有益效果有：
本摩擦热熔装置通过驱动电机带动摩擦片与产热盘摩擦生热，在常规的PE管热熔焊接的加热阶段，利用摩擦热熔装置替换加热板，在两根待焊PE管中间引入产热盘并紧密接触，通过驱动电机高速旋转摩擦生热，以使待焊PE管件端面热熔，以达到相互连接的目的，由于是旋转摩擦产热，在相同的旋转半径内，各个位置的线速度相同，因此摩擦热输入相同，可解决加热板的温度不均匀性、显示偏差、温度波动等问题；而且摩擦产热速度快于电加热，在较短时间内即可完成焊接过程，无需等待过程，相比原先热熔焊过程大幅提高了焊接效率，并且进一步节省了电量消耗。
附图说明
下面结合附图及具体实施例对本发明作进一步说明，其中：
图1是本发明实施例的结构示意图；
图2是本发明实施例的分解示意图；
图3是本发明实施例中产热盘与待焊PE管件的配合示意图。
具体实施方式
参见图1，本发明的一种PE管的摩擦热熔装置，包括支架1和安装在支架1上的驱动电机2，所述驱动电机2的输出轴连接主动轮3，所述主动轮3通过皮带4连接从动轮5，所述从动轮5的中心安装有齿轮轴6，所述齿轮轴6的两端均啮合有固定盘7。
进一步参见图2，所述固定盘7外侧固定安装有摩擦片8，固定盘7与摩擦片8之间通过铆钉固定，所述从动轮5两侧均设有至少两个套筒9，本实施例中，所述从动轮5两侧均设有四个套筒9，四个套筒9均匀地分布在从动轮5的上下左右侧，所述套筒9内套设有压簧10，所述压簧10一端抵顶在从动轮5上，所述固定盘7内侧开设有定位槽12，所述压簧10的另一端对应抵顶在定位槽12内，所述支架1位于两块摩擦片8外侧分别固定安装有两块产热盘11，所述摩擦片8与产热盘11在压簧10的作用下紧密接触。
进一步参见图3，本发明还公开了一种PE管的摩擦热熔方法，该方法包括：
步骤一、首先清洁待焊PE管件13表面的油污污染物或泥土污染物，装夹待焊PE管件13，保证同轴度与圆度不超过公差范围，切削并修整管道端面，保证端面的平直以及轴线的垂直；
步骤二、将摩擦热熔装置固定于两根待焊PE管件之间，待焊PE管件的待焊端面与产热盘的外表面保持接触；
步骤三、通过对待焊PE管件施加较高的压力P1，使待焊PE管件的待焊端面与产热盘的外表面紧密接触，并保持压力P1不变，启动驱动电机2，使主动轮3、从动轮5、齿轮轴6、固定盘7和摩擦片8高速旋转，对产热盘11摩擦产热，当待焊PE管件的塑料达到熔融状态，并开始向外侧流动时，降低压力至P2；
步骤四、当达到设定的摩擦时间后，待焊PE管件已具有一定的塑性层厚度，停止驱动电机2并移出摩擦热熔装置；
步骤五、在顶锻压力P3的作用下，将两根待焊PE管件的待焊端面对接，并保持P3一定时间，使两根待焊PE管件紧密连接在一起。
由于在从动轮5上的套筒9内放置了压簧10，压簧10产生轴向力F1迫使摩擦片8与产热盘11紧密接触，如图3所示的a中本身也存在一个轴向压力P1，摩擦片8在高速旋转的时候，就能在摩擦片8与产热盘11间产生较大的摩擦力F=μ（F1+ P1），从而摩擦产热，以使待焊PE管件13的端面热熔，由于是旋转摩擦产热，在相同的旋转半径内，各个位置的线速度相同，因此摩擦热输入相同，可解决加热板的温度不均匀性、显示偏差、温度波动等问题；而且摩擦产热速度快于电加热，在较短时间内即可完成焊接过程，无需等待过程，传统加热板需要提前15min预热，再用于加热待焊PE管件13，相比原先热熔焊过程大幅提高了焊接效率，并且进一步节省了电量消耗。
以上所述，只是本发明的较佳实施方式而已，但本发明并不限于上述实施例，只要其以任何相同或相似手段达到本发明的技术效果，都应属于本发明的保护范围。

Claims (4)

1.一种PE管的摩擦热熔装置，其特征在于：包括支架和安装在支架上的驱动电机，所述驱动电机的输出轴连接主动轮，所述主动轮通过皮带连接从动轮，所述从动轮的中心安装有齿轮轴，所述齿轮轴的两端均啮合有固定盘，所述固定盘外侧固定安装有摩擦片，所述从动轮两侧均设有至少两个套筒，所述套筒内套设有压簧，所述压簧一端抵顶在从动轮上，另一端抵顶在固定盘上，所述支架位于两块摩擦片外侧分别固定安装有两块产热盘，所述摩擦片与产热盘紧密接触，两块所述产热盘的外表面分别用于与两根待焊PE管件的待焊端面紧密接触以使两根待焊PE管件的待焊端面热熔并对接。
2.根据权利要求1所述的一种PE管的摩擦热熔装置，其特征在于：所述固定盘内侧开设有定位槽，所述压簧的另一端对应抵顶在定位槽内。
3.根据权利要求2所述的一种PE管的摩擦热熔装置，其特征在于：所述从动轮两侧均设有四个套筒。
4.一种PE管的摩擦热熔方法，其特征在于：所述方法采用权利要求1-3任一项所述的一种PE管的摩擦热熔装置，该方法包括：
步骤一、首先清洁待焊PE管件表面的油污污染物或泥土污染物，装夹待焊PE管件，保证同轴度与圆度不超过公差范围，切削并修整管道端面，保证端面的平直以及轴线的垂直；
步骤二、将摩擦热熔装置固定于两根待焊PE管件之间，待焊PE管件的待焊端面与产热盘的外表面保持接触；
步骤三、通过对待焊PE管件施加较高的压力P1，使待焊PE管件的待焊端面与产热盘的外表面紧密接触，并保持压力P1不变，启动驱动电机，使主动轮、从动轮、齿轮轴、固定盘和摩擦片高速旋转，对产热盘摩擦产热，当待焊PE管件的塑料达到熔融状态，并开始向外侧流动时，降低压力至P2；
步骤四、当达到设定的摩擦时间后，待焊PE管件已具有一定的塑性层厚度，停止驱动电机并移出摩擦热熔装置；
步骤五、在顶锻压力P3的作用下，将两根待焊PE管件的待焊端面对接，并保持P3一定时间，使两根待焊PE管件紧密连接在一起。
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