CN113878316A - Manufacturing process of pipe for ship - Google Patents
Manufacturing process of pipe for ship Download PDFInfo
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- CN113878316A CN113878316A CN202111337731.1A CN202111337731A CN113878316A CN 113878316 A CN113878316 A CN 113878316A CN 202111337731 A CN202111337731 A CN 202111337731A CN 113878316 A CN113878316 A CN 113878316A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 60
- 230000000149 penetrating effect Effects 0.000 claims abstract description 5
- 238000003466 welding Methods 0.000 claims description 283
- 238000005498 polishing Methods 0.000 claims description 59
- 238000005520 cutting process Methods 0.000 claims description 47
- 230000009471 action Effects 0.000 claims description 31
- 238000012545 processing Methods 0.000 claims description 30
- 238000000034 method Methods 0.000 claims description 19
- 229910000831 Steel Inorganic materials 0.000 claims description 16
- 239000010959 steel Substances 0.000 claims description 16
- 230000007704 transition Effects 0.000 claims description 16
- 238000005452 bending Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 9
- 230000001681 protective effect Effects 0.000 claims description 9
- 238000009826 distribution Methods 0.000 claims description 8
- 230000004907 flux Effects 0.000 claims description 6
- 238000004140 cleaning Methods 0.000 claims description 2
- 238000012937 correction Methods 0.000 claims description 2
- 230000000694 effects Effects 0.000 claims description 2
- 238000009966 trimming Methods 0.000 claims description 2
- 238000002360 preparation method Methods 0.000 abstract 2
- 238000005457 optimization Methods 0.000 abstract 1
- 230000033001 locomotion Effects 0.000 description 3
- 230000005012 migration Effects 0.000 description 3
- 238000013508 migration Methods 0.000 description 3
- 238000007517 polishing process Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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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
- B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
- B23K33/004—Filling of continuous seams
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
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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
- B23K9/18—Submerged-arc welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B41/00—Component parts such as frames, beds, carriages, headstocks
- B24B41/06—Work supports, e.g. adjustable steadies
- B24B41/067—Work supports, e.g. adjustable steadies radially supporting workpieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B55/00—Safety devices for grinding or polishing machines; Accessories fitted to grinding or polishing machines for keeping tools or parts of the machine in good working condition
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B9/00—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor
- B24B9/02—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor characterised by a special design with respect to properties of materials specific to articles to be ground
- B24B9/04—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor characterised by a special design with respect to properties of materials specific to articles to be ground of metal, e.g. skate blades
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Abstract
The invention relates to a manufacturing process of a pipe for a ship, which comprises the following steps: according to the shape of the pipe to be processed, the pipe is divided into two categories, one category is a straight pipe with flanges at two ends, the other category is a non-straight pipe, and the non-straight pipe comprises but is not limited to a bent pipe, a branch pipe, a spliced bent pipe and a cabin penetrating pipe; dividing the pipe into a small-diameter pipe, a medium-diameter pipe and a large-diameter pipe according to the diameter of the pipe to be processed, wherein the small-diameter pipe is processed by a small-diameter pipe production line, the medium-diameter pipe is processed by a medium-diameter pipe production line, and the large-diameter pipe is processed by a large-diameter pipe production line; and the welded small-diameter pipe, the welded medium-diameter pipe and the welded large-diameter pipe are stored by independent finished product trays respectively. The invention has the advantages that: through carrying out optimization management to the preparation engineering of pipe, improved the automation of pipe preparation, intelligent rate of going up the line, improve the managerial efficiency, reduce invalid labor time, reduce the invalid flow of product, simultaneously, through improving automation rate and intelligent rate, reduce the labour demand.
Description
Technical Field
The invention relates to the field of ship part processing, in particular to a manufacturing process of a pipe for a ship.
Background
At present, the price of the whole ship is continuously reduced, the labor cost is continuously improved, and under the current situation, the ship is built by adopting new technology, new process and new equipment so as to improve the building quality and the working efficiency, and the core competitiveness of the shipyard is improved, so that the shipyard is a urgent task.
In the existing ship manufacturing process, the use of multiple positions or functions of the ship needs to involve pipes, such as power pipelines and system pipelines for conveying working media such as water, oil, gas and the like, cabin penetrating pipes for communicating the inside and the outside of a cabin or adjacent cabins and the like, the working conditions need to involve more or less pipes, pipes with different sizes and different shapes need to be involved, even a single pipe is involved, and a combination form of a plurality of pipes is involved, and the pipes needed to be used on the whole ship can be large, so the processing amount is large.
The existing pipe manufacturing is a construction process flow divided by work types such as cutting, assembling, electric welding, polishing and the like, the pipe transferring workload among the work types is large, the invalid waiting time is long, the working hour consumption is large, and the number of managers and auxiliary personnel causes low per capita yield; moreover, the traditional pipe manufacturing process is primarily counted, the automatic on-line rate is only about 15.9%, and if the process flow is not changed, even if intelligent equipment is completely used, the phenomenon that the current laggard output of people is always changed and the working hour consumption is reduced cannot be thoroughly changed.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a process for manufacturing a ship pipe, which can improve the processing efficiency and reduce the ineffective labor.
In order to solve the technical problems, the technical scheme of the invention is as follows: the manufacturing process of the pipe for the ship has the innovation points that: comprises the following steps
S1: firstly, according to the shape of a pipe to be processed, the pipe is divided into two categories, one category is a straight pipe with flanges at two ends, the other category is a non-straight pipe, and the non-straight pipe comprises but is not limited to a bent pipe, a branch pipe, a spliced bent pipe and a cabin penetrating pipe;
the straight pipe processing flow is as follows: cutting a straight pipe, manually assembling, automatically or manually welding, polishing, and putting a finished product into a tray;
the non-straight pipe processing flow is as follows: cutting a straight pipe, cutting an intersecting line or bending a pipe, manually assembling, manually welding, polishing and putting a finished product into a tray;
s2: dividing the pipe into a small-diameter pipe, a medium-diameter pipe and a large-diameter pipe according to the diameter of the pipe to be processed, wherein the small-diameter pipe is processed by a small-diameter pipe production line, the medium-diameter pipe is processed by a medium-diameter pipe production line, and the large-diameter pipe is processed by a large-diameter pipe production line;
the production line of the small diameter pipes comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe bending, pipe correcting, branch pipe cutting and welding;
the production line of the medium-diameter pipe comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembly, elbow welding, pipe correction, branch pipe cutting and welding;
the large-diameter pipe production line comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe bending, pipe correcting, main pipe cutting and welding;
s3: and the welded small-diameter pipe, the welded medium-diameter pipe and the welded large-diameter pipe are stored by independent finished product trays respectively.
Further, in step S2, the small-diameter pipe production line is equipped with corresponding equipment, including a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small group stand platform, an elbow welding machine, a pipe calibration platform, a 4-inch pipe bending machine, a branch pipe cutting machine, and a medium-diameter logistics device;
the production line of the medium-diameter pipe is provided with corresponding equipment, which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform and a medium-diameter logistics device;
the large-diameter pipe production line is provided with corresponding equipment, which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform, a large-diameter logistics device and a main pipe cutting machine;
the small-diameter pipe production line and the medium-diameter pipe production line share the same medium-diameter logistics device.
Further, in step S2, before welding the pipe, the welding groove of the pipe needs to be polished by a special polishing device, where the special polishing device includes
Grinding the bracket;
the pipe placing assembly is arranged on the polishing support and comprises a processing platform arranged at the top end of the polishing support, a pair of horizontally distributed supporting rods are arranged on the upper end surface of the processing platform, two sides of each supporting rod are movably arranged on the processing platform through matching of a bearing and a bearing seat, a pair of supporting wheels are arranged on the supporting rods, and the pipes are supported through matching of the four supporting wheels;
the polishing assembly comprises a polishing platform which is installed on the polishing support and located beside the processing platform, a vertical polishing stand column is installed on the upper end face of the polishing platform, an operating rod is movably installed on the polishing stand column and horizontally arranged, a balance weight is movably connected to one side of the operating rod, a polishing machine is connected to the other side of the operating rod, and the polishing machine is located above the pipe.
Furthermore, two bracing pieces slope and distribute, its incline direction is for getting close to the central line between two bracing pieces from the one side of keeping away from the polisher gradually to make two bracing pieces be the splayed and distribute.
Further, the connection between the grinding upright post and the operating rod is as follows: the stand of polishing comprises the angle steel sheet of two vertical settings that distribute side by side jointly, and two angle steel sheet relative distributions all open the connecting hole that has a vertical distribution in two angle steel sheet one sides adjacent each other, all have a connecting rod in the both sides of action bars, and two connecting rods stretch into two connecting holes respectively and carry out the activity from top to bottom along the connecting hole, have connected gradually lock nut, a limiting plate in the tip outside-in of connecting rod, wherein, lock nut and connecting rod thread tightening, welded fastening between limiting plate and the connecting rod, lock nut and limiting plate are located the both sides of opening the one side that has the connecting hole on the angle steel sheet respectively.
Further, the connection between the operating rod and the grinding machine is as follows: still be provided with a transition connecting plate between polisher and action bars, polisher snap-on is on the transition connecting plate, and it is fixed to be connected through the cooperation of bolt and nut between transition connecting plate and the action bars.
Further, in step S2, during welding of the pipes, before welding the pipes, it is first necessary to determine a welding area of the pipes, and butt-jointing the pipes to be welded, and during butt-jointing, trimming the welding end of the pipe to be welded at the end, cutting the welding end of the pipe into an inclined plane, and forming a welding groove between the welding ends of the two pipes;
secondly, cleaning the surfaces to be welded of the two pipes and the two sides of the edge of the welding groove within 30mm before welding;
again, theWhen the welding groove is welded, the welding groove is divided into eight layers of welding seams, the welding seams corresponding to the base layer are sequentially a first layer of welding seam, a second layer of welding seam, a third layer of welding seam, a fourth layer of welding seam, a fifth layer of welding seam, a sixth layer of welding seam, a seventh layer of welding seam and an eight layer of welding seam from bottom to top, the middle positions of the fifth layer of welding seam and the sixth layer of welding seam are stacked, the seventh layer of welding seam and the eight layer of welding seam respectively correspond to the upper side walls of the two pipes, the middle positions of the seventh layer of welding seam and the eight layer of welding seam are stacked, only flux cored wire gas shield welding is used for welding or flux cored wire gas shield welding and submerged arc welding are used for welding during welding, the third layer of welding seam and the four layer of welding seam are welded through submerged arc welding during flux cored wire gas shield welding and submerged arc welding, and the other layers of welding seams are welded through CO2And welding by using the flux-cored wire in a gas shielded welding way.
Further, the one layer of weld passes through CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 240-260A, the voltage is 30-34V, and the welding speed is 20-25 cm/min;
two-layer welding seam, three-layer welding seam and four-layer welding seam passing through CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of protective gas is 20-25L/min, the current is 240-260A, the voltage is 30-34V, and the welding speed is 30-35 cm/min;
the welding conditions of the three-layer welding seam and the four-layer welding seam through submerged arc welding are as follows: the diameter of the welding wire is 5.0mm, the current is 630-650A, the voltage is 28-32V, and the welding speed is 28-32 m/h;
five-layer welding seam, six-layer welding seam, seven-layer welding seam and eight-layer welding seam pass through CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 160-180A, the voltage is 25-27V, and the welding speed is 25-28 cm/min.
The invention has the advantages that: the method of the invention improves the automation and intelligent online rate of pipe manufacturing, improves the management efficiency, reduces the invalid labor time and the invalid flow of products by optimizing and managing the pipe manufacturing engineering, and simultaneously reduces the labor demand, the per-capita yield and the unit labor hour consumption by improving the automation rate and the intelligent rate.
The method of the invention welds most pipe flanges on the assembly line, and simultaneously finishes the parts of different types of pipe splitting at different stations, so that the single station finishes the assembly and welding of the parts of single type, and then finishes the manufacture of the pipe at the large assembly and welding station; meanwhile, a process of welding before bending is also adopted, so that the production efficiency of assembling and welding the pipe flange is improved, and the on-line rate of the pipe assembly line is improved to about 80% from 15% at present.
During welding, the butt welding seams among the pipes are welded by adopting eight layers of welding seams, and different welding conditions are adopted in each layer, so that the welding fastness can be ensured, the strength during use is ensured, the defects of welding cracks and the like are not easy to occur, the welding quality is improved, and the service life is prolonged.
To dedicated grinding device, through polishing support, pipe place the subassembly, polish mutually supporting between the subassembly, realize polishing to the periphery of pipe and the tip groove, overall structure is simple, and required spare part is few, whole polishing process easy operation moreover, processes convenience very.
Adopt the mode that the splayed slope distributes to two bracing pieces to when adding man-hour, the pipe can drive the pivoted simultaneously at the polisher and automatically carry out horizontal migration to the polisher direction, need not to promote again by the manual work or other initiative driving piece promote the pipe and remove, convenient processing.
The stand of polishing and the action bars between be connected adopts mutually supporting between angle steel plate, connecting hole, connecting rod, lock nut, the limiting plate, on the basis of guaranteeing to polish stand and action bars relatively fixed, the action bars can carry out the luffing motion to conveniently polish the pipe, simultaneously, the height of action bars itself is also adjustable, thereby can adjust the height of action bars according to the size of processing pipe.
To being connected between action bars and the polisher, come the transition connection through addding a transition connecting plate to the relative angle between adjustable polisher and the action bars to two kinds of different parts of circumference outer wall and the groove of pipe are polished to and are polished to the groove of different angles, the commonality is stronger.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
FIG. 1 is a production flow chart of three production lines in the present invention.
Fig. 2 is a schematic view of a dedicated polishing device of the present invention.
FIG. 3 is a schematic view of a butt weld of the pipe of the present invention.
Detailed Description
The following examples are presented to enable one of ordinary skill in the art to more fully understand the present invention and are not intended to limit the scope of the embodiments described herein.
The manufacturing process of the pipe for the ship is realized by the following steps:
comprises the following steps
S1: firstly, according to the shape of the pipe to be processed, the pipe is divided into two categories, one category is a straight pipe with flanges at two ends, and the other category is a non-straight pipe, wherein the non-straight pipe comprises but is not limited to a bent pipe, a branch pipe, a spliced bent pipe and a cabin penetrating pipe.
The straight pipe processing flow is as follows: cutting a straight pipe, manually assembling, automatically or manually welding, polishing, and putting a finished product into a tray.
The non-straight pipe processing flow is as follows: straight pipe cutting, intersecting line cutting or pipe bending, manual assembly, manual welding, polishing and tray loading of finished products.
S2: then, according to the diameter of the pipe to be processed, the pipe is divided into a small-diameter pipe, a medium-diameter pipe and a large-diameter pipe, wherein the small-diameter pipe is processed by a small-diameter pipe production line, the medium-diameter pipe is processed by a medium-diameter pipe production line, and the large-diameter pipe is processed by a large-diameter pipe production line, as shown in fig. 1.
The production line of the small diameter pipe comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe bending, pipe correcting, branch pipe cutting and welding.
The small-diameter pipe production line is provided with corresponding equipment which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform, a 4-inch pipe bending machine, a branch pipe cutting machine and a medium-diameter logistics device.
The production line of the medium-diameter pipe comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe correcting, branch pipe cutting and welding.
The medium-diameter pipe production line is provided with corresponding equipment which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform and a medium-diameter logistics device.
The production line of the large-diameter pipe comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe bending, pipe correcting, main pipe cutting and welding.
The large-diameter pipe production line is provided with corresponding equipment which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform, a large-diameter logistics device and a main pipe cutting machine.
In foretell small-diameter pipe production line, well footpath pipe production line, big footpath pipe production line, the same cover well footpath commodity circulation device of path pipe production line and well footpath pipe production line sharing, well footpath commodity circulation device is the same with big footpath commodity circulation device's structure, all can adopt the conveyer belt to carry out the commodity circulation.
Before the pipes are welded, the welding groove of the pipes needs to be polished by a special polishing device, as can be seen from the schematic diagram shown in fig. 2, the special polishing device comprises
A support 1 of polishing, this support 1 of polishing include three stand that are the distribution of article font, and three stand all inclines to set up, and its incline direction is drawn close to the central line direction between the three stand gradually from bottom to top, connects through a horizontal post between two adjacent stands.
The utility model provides an install the pipe place the subassembly on support 1 of polishing, the pipe is placed the subassembly and is included one and install the processing platform 2 on support 1 top of polishing, processing platform 2 is a rectangular shaped plate, install a pair of horizontal distribution's bracing piece 3 on the up end of processing platform 2, bracing piece 3 extends along the major axis direction of processing platform 2, the cooperation movable mounting that all passes through bearing and bearing frame in the up end of processing platform 2 in the both sides of bracing piece 3, the bearing frame passes through the bolt fastening on processing platform 2, install a pair of supporting wheel 4 on bracing piece 3, and two supporting wheels 4 on two bracing pieces 3 all stagger the distribution, realize the support to the pipe jointly through the cooperation of four supporting wheels 4, adopt this kind of the mode of distribution that staggers, thereby can increase the strong point to the pipe, ensure the support of pipe.
Two bracing pieces 3 slope and distribute, the incline direction of bracing piece 3 is for getting close to the central line between two bracing pieces 3 gradually from one side of keeping away from polisher 5 to make two bracing pieces 3 be the splayed and distribute. Adopt the mode that the splayed slope distributes to two bracing pieces 3 to when adding man-hour, the pipe can drive the pivoted simultaneously at polisher 5 and automatically carry out horizontal migration to the polisher direction, need not to promote again by the manual work or other initiative driving piece promote the pipe and remove, convenient processing.
The utility model provides an install the subassembly of polishing on polishing support 1, the subassembly of polishing includes that one is installed on polishing support 1 and is located the platform 6 of polishing of 2 sides of processing platform, and platform 6 of polishing is a rectangular shaped plate, installs the vertical stand of polishing that upwards extends on the up end of platform 6 of polishing, and movable mounting has the action bars 8 that a level set up on the stand of polishing, and the stand of polishing is connected between 8 with the action bars and is: the polishing upright column is composed of two angle steel plates 7 which are vertically arranged and distributed in parallel, the two angle steel plates 7 are distributed oppositely, the bottom ends of the angle steel plates 7 are directly welded on the upper end surface of the polishing platform 6, one side, adjacent to each other, of each of the two angle steel plates 7 is provided with a connecting hole 9 which is vertically distributed, two sides of an operating rod 8 are provided with connecting rods 11, the two connecting rods 11 respectively extend into the two connecting holes 9, the connecting rods 11 can move up and down in the connecting holes 9, the end part of each connecting rod 11 is sequentially connected with a locking nut 10 and a limiting plate 12 from outside to inside, wherein the locking nut 10 is in threaded fixation with the connecting rods 11, the outer wall of the end part of each connecting rod 11 is also provided with an external thread structure, the limiting plate 12 is directly welded and fixed with the connecting rods 11, and the locking nut 10 and the limiting plate 12 are respectively positioned on two sides, provided with the side, provided with the connecting holes 9, on the angle steel plates 7, a backing plate is arranged between the locking nut 10 and the angle steel plate 7, and the sizes of the locking nut 10 and the limiting plate 12 are both larger than the width of the connecting hole 9. To polishing being connected between stand and the action bars 8, adopt angle steel plate 7, connecting hole 9, connecting rod 11, lock nut 10, mutually support between the limiting plate 12, on the basis of guaranteeing to polish stand and action bars 8 relatively fixed, action bars 8 can carry out the luffing motion, in order to conveniently polish the pipe, and simultaneously, the height of action bars 8 itself is also adjustable, when adjusting, need loosen two lock nut 10 respectively, then reciprocate by personnel's handheld action bars 8, and after removing and targetting in place, reuse lock nut 10 to lock and can accomplish the regulation, thereby can adjust the height of action bars according to the size of the pipe of treating processing.
One side swing joint of action bars 8 has a counter weight 13, and counter weight 13 hangs at the tip of action bars 8 through rope 14, still opens the recess that holds rope 14 embedding simultaneously at the tip of action bars 8, and the design of counter weight 13 is then for the convenience personnel more laborsaving when operating polisher 5, and the opposite side of action bars 8 is connected with a polisher 5, and polisher 5 is located the top of pipe, and the connection between action bars 8 and polisher 5 does: a transition connecting plate 15 is further arranged between the grinding machine 5 and the operating rod 8, the grinding machine 5 is directly fixed on the transition connecting plate 15, and the transition connecting plate 15 and the operating rod 8 are fixedly connected through matching of bolts and nuts. To being connected between action bars 8 and polisher 5, through addding a transition connecting plate 15 and come the transition connection, thereby relative angle between adjustable polisher 5 and the action bars 8, in order to make things convenient for two kinds of different parts of circumference outer wall and groove to polish to the pipe, and polish to the groove of different angles, the commonality is stronger, when adjusting, at first loosen transition connecting plate 15 and the nut of 8 connection usefulness of action bars, then rotate transition connecting plate 15, corresponding polisher 5 also can rotate along with transition connecting plate 15, after the turned angle targets in place, reuse nut will pass through and lock between connecting plate 15 and the action bars 8, thereby accomplish the regulation, unusual convenience.
When polishing, at first place the pipe of treating processing between two bracing pieces 3, and support on four supporting wheels 4, and place the terminal surface of pipe in the below of polisher 5, then, it pushes down to hand polisher 5 by the manual work, polish from utilizing polisher 5 to the surface of pipe, and at the in-process of polishing, the rotation of the polishing blade of polisher 5 can drive the pipe and rotate, and the pipe when rotatory, can carry out horizontal migration to polisher 5 direction along bracing piece 3, thereby need not again by the manual work to promote the pipe and remove, processing has made things convenient for.
When the two support rods 3 are distributed in a splayed manner, the offset amplitude between the two support rods 3 is small, namely the two support rods are close to the parallel state of the two support rods 3, and the support wheels 4 are distributed in a staggered manner, namely the support wheels 4 are not on the same straight line, so that the support of points at 4 different positions of the pipe is realized through the four support wheels 4; when the support rods 3 distributed in the shape of the Chinese character 'ba' are adopted to support the pipes, the heights of the pipes and the support points on the support rods 3 are inconsistent, namely the pipes are high at one side and low at the other side, under the condition, when the pipes rotate, the pipes naturally walk to the low side, and therefore the horizontal movement is realized; in addition, the whole cutting die only needs to polish the end of the pipe, namely, the walking distance is short, the pipe is long and has certain weight, so that the pipe only needs to be supported on the supporting rod 3, and the polishing process is manually performed by workers, namely, the workers still participate in the polishing process, and the pipe does not need to be fixed.
When a pipe is welded, before the pipe is welded, firstly, the welding area of the pipe needs to be determined, the pipe to be welded is butted, during the butt joint, the welding end of the pipe of which the end part needs to be welded is subjected to edge cutting, the welding end of the pipe is cut into an inclined plane, and a welding groove is formed between the welding ends of the two pipes.
Secondly, the surfaces to be welded of the two pipes and the two sides of the edge of the welding groove are cleaned within 30mm before welding.
Thirdly, welding the grooveDuring welding, the welding groove is divided into eight layers of welding seams, the welding seams corresponding to the base layer are sequentially a first layer of welding seam 21, a second layer of welding seam 22, a third layer of welding seam 23, a fourth layer of welding seam 24, a fifth layer of welding seam 25, a sixth layer of welding seam 26, a seventh layer of welding seam 27 and an eighth layer of welding seam 28 from bottom to top, the middle positions of the fifth layer of welding seam 25 and the sixth layer of welding seam 26 are stacked, the seventh layer of welding seam 27 and the eighth layer of welding seam 28 respectively correspond to the upper side walls of the two pipes, the middle positions of the seventh layer of welding seam 27 and the eighth layer of welding seam 28 are stacked, during welding, only flux-cored wire gas shielded welding or flux-cored wire gas shielded welding and submerged arc welding are used, during flux-cored wire gas shielded welding and submerged arc welding, the third layer of welding seam 23 and the fourth layer of welding seam 24 are welded through submerged arc welding, and the other layers of welding seams are welded through CO2And welding by using the flux-cored wire in a gas shielded welding way.
When welding the eight-layer welding seam, after welding of each layer of welding seam is finished, welding slag, spatter and burrs need to be removed, and then the next layer of welding seam is welded.
One layer of weld 21 passing CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 240-260A, the voltage is 30-34V, and the welding speed is 20-25 cm/min.
The two-layer welding seam 22, the three-layer welding seam 23 and the four-layer welding seam 24 pass through CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 240-260A, the voltage is 30-34V, and the welding speed is 30-35 cm/min.
The welding conditions of the three-layer welding seam 23 and the four-layer welding seam 24 by submerged arc welding are as follows: the diameter of the welding wire is 5.0mm, the current is 630-650A, the voltage is 28-32V, and the welding speed is 28-32 m/h.
Five-layer weld 25, six-layer weld 26, seven-layer weld 27, and eight-layer weld 28 pass CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 160-180A, the voltage is 25-27V, and the welding speed is 25-28 cm/min.
During welding, the butt welding seams among the pipes are welded by adopting eight layers of welding seams, and different welding conditions are adopted in each layer, so that the welding fastness can be ensured, the strength during use is ensured, the defects of welding cracks and the like are not easy to occur, the welding quality is improved, and the service life is prolonged.
S3: and the welded small-diameter pipe, the welded medium-diameter pipe and the welded large-diameter pipe are stored by independent finished product trays respectively.
The method of the invention improves the automation and intelligent online rate of pipe manufacturing, improves the management efficiency, reduces the invalid labor time and the invalid flow of products by optimizing and managing the pipe manufacturing engineering, and simultaneously reduces the labor demand, the per-capita yield and the unit labor hour consumption by improving the automation rate and the intelligent rate.
The method of the invention welds most pipe flanges on the assembly line, and simultaneously finishes the parts of different types of pipe splitting at different stations, so that the single station finishes the assembly and welding of the parts of single type, and then finishes the manufacture of the pipe at the large assembly and welding station; meanwhile, a process of welding before bending is also adopted, so that the production efficiency of assembling and welding the pipe flange is improved, and the on-line rate of the pipe assembly line is improved to about 80% from 15% at present.
It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (8)
1. A manufacturing process of a pipe for a ship is characterized by comprising the following steps: comprises the following steps
S1: firstly, according to the shape of a pipe to be processed, the pipe is divided into two categories, one category is a straight pipe with flanges at two ends, the other category is a non-straight pipe, and the non-straight pipe comprises but is not limited to a bent pipe, a branch pipe, a spliced bent pipe and a cabin penetrating pipe;
the straight pipe processing flow is as follows: cutting a straight pipe, manually assembling, automatically or manually welding, polishing, and putting a finished product into a tray;
the non-straight pipe processing flow is as follows: cutting a straight pipe, cutting an intersecting line or bending a pipe, manually assembling, manually welding, polishing and putting a finished product into a tray;
s2: dividing the pipe into a small-diameter pipe, a medium-diameter pipe and a large-diameter pipe according to the diameter of the pipe to be processed, wherein the small-diameter pipe is processed by a small-diameter pipe production line, the medium-diameter pipe is processed by a medium-diameter pipe production line, and the large-diameter pipe is processed by a large-diameter pipe production line;
the production line of the small diameter pipes comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe bending, pipe correcting, branch pipe cutting and welding;
the production line of the medium-diameter pipe comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembly, elbow welding, pipe correction, branch pipe cutting and welding;
the large-diameter pipe production line comprises cutting, flange positioning, flange welding, short pipe positioning, short pipe welding, small assembling, elbow welding, pipe bending, pipe correcting, main pipe cutting and welding;
s3: and the welded small-diameter pipe, the welded medium-diameter pipe and the welded large-diameter pipe are stored by independent finished product trays respectively.
2. The process for producing a pipe for a ship according to claim 1, wherein: in the step S2, the small-diameter pipe production line is equipped with corresponding equipment, including a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small erecting platform, an elbow welding machine, a pipe correcting platform, a 4-inch pipe bending machine, a branch pipe cutting machine, and a medium-diameter logistics device;
the production line of the medium-diameter pipe is provided with corresponding equipment, which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform and a medium-diameter logistics device;
the large-diameter pipe production line is provided with corresponding equipment, which comprises a flame cutting machine, a rotary material rack, a flange positioning machine, a flange straight pipe welding machine, a small vertical platform, an elbow welding machine, a pipe correcting platform, a large-diameter logistics device and a main pipe cutting machine;
the small-diameter pipe production line and the medium-diameter pipe production line share the same medium-diameter logistics device.
3. The process for producing a pipe for a ship according to claim 1, wherein: in step S2, before welding the pipe, a special polishing device is required to polish the welding groove of the pipe, where the special polishing device includes
Grinding the bracket;
the pipe placing assembly is arranged on the polishing support and comprises a processing platform arranged at the top end of the polishing support, a pair of horizontally distributed supporting rods are arranged on the upper end surface of the processing platform, two sides of each supporting rod are movably arranged on the processing platform through matching of a bearing and a bearing seat, a pair of supporting wheels are arranged on the supporting rods, and the pipes are supported through matching of the four supporting wheels;
the polishing assembly comprises a polishing platform which is installed on the polishing support and located beside the processing platform, a vertical polishing stand column is installed on the upper end face of the polishing platform, an operating rod is movably installed on the polishing stand column and horizontally arranged, a balance weight is movably connected to one side of the operating rod, a polishing machine is connected to the other side of the operating rod, and the polishing machine is located above the pipe.
4. The process for producing a pipe for a ship according to claim 3, wherein: the two support rods are distributed in an inclined mode, and the inclined direction of the two support rods is gradually close to the central line between the two support rods from one side far away from the grinding machine, so that the two support rods are distributed in a splayed mode.
5. The process for producing a pipe for a ship according to claim 3, wherein: the connection between the grinding upright post and the operating rod is as follows: the stand of polishing comprises the angle steel sheet of two vertical settings that distribute side by side jointly, and two angle steel sheet relative distributions all open the connecting hole that has a vertical distribution in two angle steel sheet one sides adjacent each other, all have a connecting rod in the both sides of action bars, and two connecting rods stretch into two connecting holes respectively and carry out the activity from top to bottom along the connecting hole, have connected gradually lock nut, a limiting plate in the tip outside-in of connecting rod, wherein, lock nut and connecting rod thread tightening, welded fastening between limiting plate and the connecting rod, lock nut and limiting plate are located the both sides of opening the one side that has the connecting hole on the angle steel sheet respectively.
6. The process for producing a pipe for a ship according to claim 3, wherein: the connection between action bars and polisher does: still be provided with a transition connecting plate between polisher and action bars, polisher snap-on is on the transition connecting plate, and it is fixed to be connected through the cooperation of bolt and nut between transition connecting plate and the action bars.
7. The process for producing a pipe for a ship according to claim 1, wherein: in step S2, during welding of the pipes, before welding the pipes, firstly determining a welding area of the pipes, and butting the pipes to be welded together, during butting, trimming the welding ends of the pipes to be welded together, cutting the welding ends of the pipes into inclined surfaces, and forming a welding groove between the welding ends of the two pipes;
secondly, cleaning the surfaces to be welded of the two pipes and the two sides of the edge of the welding groove within 30mm before welding;
thirdly, when the welding groove is welded, the welding groove is divided into eight layers of welding seams, the welding seams corresponding to the base layer are sequentially a first layer of welding seam, a second layer of welding seam, a third layer of welding seam, a fourth layer of welding seam, a fifth layer of welding seam, a sixth layer of welding seam, a seventh layer of welding seam and an eight layer of welding seam from bottom to top, the middle positions of the fifth layer of welding seam and the sixth layer of welding seam are stacked, the seventh layer of welding seam and the eight layer of welding seam respectively correspond to the upper side walls of the two pipes, the middle positions of the seventh layer of welding seam and the eight layer of welding seam are stacked, only flux cored wire gas shield welding or flux cored wire gas shield welding and submerged arc welding are used during welding, and flux cored wire gas shield welding and submerged arc welding are usedWhen in use, the three-layer welding seam and the four-layer welding seam are welded by submerged arc welding, and the other layers of welding seams are welded by CO2And welding by using the flux-cored wire in a gas shielded welding way.
8. The process for producing a pipe for a ship according to claim 7, wherein: the one layer weld passes CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 240-260A, the voltage is 30-34V, and the welding speed is 20-25 cm/min;
two-layer welding seam, three-layer welding seam and four-layer welding seam passing through CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of protective gas is 20-25L/min, the current is 240-260A, the voltage is 30-34V, and the welding speed is 30-35 cm/min;
the welding conditions of the three-layer welding seam and the four-layer welding seam through submerged arc welding are as follows: the diameter of the welding wire is 5.0mm, the current is 630-650A, the voltage is 28-32V, and the welding speed is 28-32 m/h;
five-layer welding seam, six-layer welding seam, seven-layer welding seam and eight-layer welding seam pass through CO2The welding conditions of the flux-cored wire gas shield welding are as follows: the diameter of the welding wire is 1.2mm, the flow of the protective gas is 20-25L/min, the current is 160-180A, the voltage is 25-27V, and the welding speed is 25-28 cm/min.
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| CN202111337731.1A CN113878316A (en) | 2021-11-12 | 2021-11-12 | Manufacturing process of pipe for ship |
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| CN202111337731.1A CN113878316A (en) | 2021-11-12 | 2021-11-12 | Manufacturing process of pipe for ship |
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Cited By (1)
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| CN116690121A (en) * | 2023-07-14 | 2023-09-05 | 广东大洋医疗科技股份有限公司 | Production and processing technology of special-shaped bracket |
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