CN113883409A - Aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed and manufacturing method thereof - Google Patents
Aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed and manufacturing method thereof Download PDFInfo
- Publication number
- CN113883409A CN113883409A CN202111013441.1A CN202111013441A CN113883409A CN 113883409 A CN113883409 A CN 113883409A CN 202111013441 A CN202111013441 A CN 202111013441A CN 113883409 A CN113883409 A CN 113883409A
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- Prior art keywords
- spinning
- aluminum alloy
- gas cylinder
- inner container
- pressure
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Images
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- F17C2270/0184—Fuel cells
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/32—Hydrogen storage
Abstract
The application provides an aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed and a manufacturing method thereof. This aluminum alloy inner bag high pressure full winding gas cylinder of one end back cover includes: the aluminum alloy liner, the composite material reinforcing layer and the external protective layer; the aluminum alloy inner bag is the seamless structure of integral type of one end back cover, other end binding off shaping head and bottleneck, includes: the bottle comprises a bottle mouth, an end enclosure, a straight cylinder section and a back cover, wherein the end enclosure and the back cover are respectively positioned at two ends of the straight cylinder section, and the bottle mouth is positioned on the end enclosure; the composite material reinforcing layer is coated on the outer side of the aluminum alloy inner container, wherein the composite material reinforcing layer is formed by winding carbon fibers in a spiral and annular combined winding mode and curing resin; the outer protective layer is coated on the outer side of the composite material reinforcing layer, wherein the outer protective layer is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin.
Description
Technical Field
The application relates to the technical field of high-pressure containers, in particular to an aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed and a manufacturing method thereof.
Background
The high-pressure gas cylinder is widely used in various industries of national economy such as industrial and mining production, construction, transportation, ocean, aviation, medical treatment, military and the like. The capacity, wall thickness, and fabrication process and materials of a high pressure gas cylinder all affect the performance of the high pressure gas cylinder. Such as natural gas and hydrogen, is a clean energy source that is heavily developed and widely used worldwide. The use of 20-30MP high pressure gas cylinders for storage and transportation and the use of Compressed Natural Gas (CNG), compressed hydrogen and other compressed industrial gases is currently the primary means by which these gases are transported from main pipelines to points of use, filling stations, etc.
At present, the carbon fiber fully-wound high-pressure gas cylinder with the aluminum alloy liner has a plurality of advantages, gradually replaces the traditional steel gas cylinder, and becomes the mainstream product of the high-pressure gas cylinder in the world. Its advantages are as follows:
(1) the weight is greatly reduced; the gas cylinder compositely wound by the aluminum alloy liner has the material thickness of 50-70% of that of the steel cylinder and lower density under the same performance, so that the weight of the gas cylinder is only 35-40% of that of the traditional steel cylinder.
(2) The damage safety is good; the aluminum alloy inner container carbon fiber fully-wound gas cylinder is reinforced by the aluminum alloy inner container and the carbon fiber composite material, fibers per square centimeter are as many as thousands of fibers, when the gas cylinder is overloaded and a small amount of fibers are broken, the load of the gas cylinder can be rapidly distributed on the fibers which are not damaged, so that the gas cylinder cannot lose the bearing capacity in a short period or even a long period, and the safety is greatly improved.
(3) The shock absorption is good; the interface of the fiber and the resin matrix in the composite material has shock absorption capacity, good shock damping and high sound-shock fatigue resistance.
(4) Compared with the complex process required by a seamless steel gas cylinder, the fiber winding process is more flexible, easy to change, simpler in process, easy to realize automation and far lower in energy consumption than the production process of the steel gas cylinder.
For example, the aluminum alloy liner carbon fiber fully-wound gas cylinder with the outer diameter phi of 406-phi 850mm and the length of not more than 5m is mainly used as a CNG fuel gas cylinder for a large-scale natural gas automobile, a modularized CNG gas cylinder group storage and transportation gas cylinder and the like for mobile use of a large-volume high-pressure gas cylinder.
However, limited by technical capabilities of materials, production and the like, China cannot produce the carbon fiber fully-wound gas cylinder with the aluminum alloy liner with the diameter larger than phi 406mm at present, and the core problem is that the aluminum alloy liner cannot be manufactured. In order to further master key technologies and products of large storage and transportation devices for compressed natural gas, hydrogen, mixed gas and the like with independent intellectual property rights, the aluminum alloy liner product for the high-pressure gas cylinder with the characteristics of large diameter, long length, light weight, high reliability and the like is urgently required to be developed.
Disclosure of Invention
The application aims to provide an aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed and a manufacturing method thereof, so as to solve or alleviate the problems in the prior art.
In order to achieve the above purpose, the present application provides the following technical solutions:
the application provides an aluminum alloy inner bag high pressure full winding gas cylinder of one end back cover, include: the aluminum alloy liner, the composite material reinforcing layer and the external protective layer; the aluminum alloy inner bag is the seamless structure of integral type of one end back cover, other end binding off shaping head and bottleneck, includes: the bottle comprises a bottle mouth, a sealing head, a straight cylinder section, a back cover and a back cover, wherein the sealing head and the back cover are respectively positioned at two ends of the straight cylinder section, and the bottle mouth is positioned on the sealing head; the length of the aluminum alloy inner container is less than 5 meters, the nominal outer diameter of the straight cylinder section is phi 406-phi 850mm, and the rated pressure of the high-pressure gas cylinder is 20-30 Mpa; the method comprises the following steps of preparing a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end by adopting reverse extrusion forming, carrying out multi-pass strong external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control strong external spinning press to obtain an aluminum alloy inner container spinning pipe, and carrying out scratch and collision grinding on the inner and outer surfaces of the aluminum alloy inner container spinning pipe with surface defects detected by adopting a numerical control inner and outer circle grinding machine after the fixed-length processing, cleaning and defect inspection of the aluminum alloy inner container spinning pipe; when the aluminum alloy inner container spinning tube is ground, the aluminum alloy inner container spinning tube is driven to rotate, the inner circle grinding mechanism is driven to carry out positioning on the detected inner surface defects through visual detection equipment, and point-by-point grinding is carried out according to the positioned positions; during grinding, the aluminum alloy liner spinning pipe swings at the speed of 30r/min within the angle range of (-10 degrees and 10 degrees); driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the detected outer surface defects, and continuously grinding according to the positioned position; the composite material reinforcing layer is coated on the outer side of the aluminum alloy inner container, wherein the composite material reinforcing layer is formed by winding carbon fibers in a spiral and annular combined winding mode and curing the carbon fibers with resin; the outer protective layer is coated on the outer side of the composite material reinforcing layer, wherein the outer protective layer is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin.
The embodiment of the present application further provides a method for manufacturing an aluminum alloy liner high-pressure fully-wound gas cylinder with one end sealed, which is used for manufacturing any one of the aluminum alloy liner high-pressure fully-wound gas cylinders with one end sealed, and comprises:
step S1, carrying out integral reverse extrusion forming on the blank with the back cover;
the step S1: adopting a heating backward extrusion process combined with turning and boring processes to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end; the method specifically comprises the following steps:
heating an aluminum ingot, and preheating the aluminum ingot to be extruded to 200-400 ℃;
heating the mold, and preheating the outer extrusion mold and the inner extrusion rod to 200-400 ℃;
extrusion molding, namely placing an aluminum ingot in an extrusion die, and extruding the blank for multiple times into a prefabricated pipe blank with a bottom seal under the condition of continuous heating and temperature preservation;
processing the outer surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a turning method;
processing the inner surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a boring method to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end;
step S2, preparing an aluminum alloy inner container spinning pipe: carrying out multi-pass powerful external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control powerful external spinning machine to obtain an aluminum alloy inner container spinning pipe;
step S3, closing the end socket and spinning and forming the bottle mouth: spinning and forming the end socket and the bottle mouth at the opening of the aluminum alloy liner spinning tube by adopting a heating closing-up spinning machine to obtain a second spinning piece;
step S4, processing a central hole of the bottle mouth: machining a central hole of the bottle opening of the second spinning piece obtained in the step S2 to obtain a third spinning piece;
step S5, curved surface flaw detection: performing closing quality flaw detection on the third spinning part obtained in the step S4, and checking whether a machining defect exists at the end socket position;
step S6, grinding the inner surface of the curved surface: grinding the inner surface defects of the end socket found in the step S5 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third rotary pressing piece with qualified quality;
step S7, heat treatment: carrying out T6 process treatment on the third spinning piece obtained in the step S6 to obtain an aluminum alloy inner container blank;
step S8, processing bottle mouth: respectively machining the inner diameter and the outer diameter of the bottle mouth of the aluminum alloy liner blank obtained in the step S7 by using a special bottle mouth machining center, and machining threads in the bottle mouth to obtain an aluminum alloy liner;
step S9, cleaning the inner container, namely, performing high-pressure water spraying cleaning on the inner cavity of the aluminum alloy inner container for the oversized high-pressure gas cylinder obtained in the step S8 by using a special horizontal gas cylinder inner container cleaning machine to remove aluminum scraps and other processing pollutants, and drying; the method comprises the following steps:
step 901, vertically placing the aluminum alloy liner on a special vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder liner cleaning machine to enter the aluminum alloy liner, and fixing the aluminum alloy liner;
s902, cleaning the inner cavity of the aluminum alloy inner container by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove processing pollutants;
step S903, after the cleaning is finished, starting the turnover frame to incline to 45 degrees, enabling the end sealing end to face downwards, and pouring water;
and step S904, drying the liner by adopting an inward extending type steam dryer.
Step S10, checking the semi-finished product: performing sampling inspection on the aluminum alloy inner container obtained in the step S9, measuring the texture grain sizes of any six positions of the aluminum alloy inner container subjected to sampling inspection, and measuring the tensile strength, yield strength and elongation of the straight cylinder section of the aluminum alloy inner container subjected to sampling inspection; wherein the tensile strength of the straight cylinder section of the aluminum alloy liner is not less than 345MPa, the yield strength is not less than 310MPa, and the elongation is less than 16%;
step S11, preprocessing the inner container: horizontally placing the aluminum alloy liner in the step S10 on a coating station of special automatic coating and drying equipment by adopting the special automatic coating and drying equipment, and coating the aluminum alloy liner with an anti-galvanic corrosion coating;
step S12, carbon fiber winding: adopting a numerical control automatic winding machine to perform carbon fiber winding processing on the aluminum alloy inner container coated with the anti-galvanic corrosion layer in the step S11 in a winding mode of combining spiral and annular directions to form a composite material reinforcing layer of the gas cylinder;
step S13, winding glass fiber: carrying out glass fiber winding processing on the gas cylinder semi-finished product of the multi-layer carbon fiber wound in the step S12 in a spiral and annular combined winding mode by using a numerical control automatic winding machine to form an external protective layer of the gas cylinder;
step S14, curing: based on a stepped temperature rise and drop curve, a box-type heating furnace with a function of supporting the gas cylinder to automatically rotate in the furnace is adopted to solidify the gas cylinder;
step S15, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests on the gas cylinder one by one;
step S16, airtight test: carrying out air tightness leakage detection tests on the air cylinders one by adopting an integrated air tightness testing machine with an explosion-proof function;
step S17, fatigue test: performing sampling inspection verification on the fatigue performance of the gas cylinder by adopting a fatigue pressure cycle tester according to the proportion of one gas cylinder in each batch;
step S18, blasting test: and (4) performing selective inspection verification on the blasting performance of the gas cylinder by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch.
Compared with the closest prior art, the technical scheme of the embodiment of the application has the following beneficial effects:
according to the technical scheme provided by the embodiment of the application, the aluminum alloy liner with the integral seamless structure and the end socket and the bottle mouth formed by closing up two ends is manufactured by adopting composite processing methods of spinning, winding, curing and the like, carbon fibers are wound on the outer side of the aluminum alloy liner in a spiral and annular combined winding mode and are cured by resin to form a composite material reinforcing layer coated on the aluminum alloy liner; and winding glass fiber in a spiral and annular combined winding mode at the outer side of the composite material reinforcing layer and curing the glass fiber by resin to form an outer protective layer for coating the composite material reinforcing layer. The whole manufacturing process has the advantages of simple preparation process, convenient operation, low energy consumption, little pollution, less loss of raw materials and great saving of raw material cost. Meanwhile, because one end is provided with the back cover, the length of the gas cylinder is reduced, and the gas storage capacity is increased.
According to the manufacturing method of the aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed, the aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed is processed, the nominal outer diameter is phi 406-phi 850mm, and the volume of the processed aluminum alloy inner container high-pressure fully-wound gas cylinder is far higher than that of the existing standard aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed; the device has the characteristics of high pressure bearing capacity, high reliability, thin wall and light weight; the texture grain size of any position of the aluminum alloy liner is more than or equal to 5 grade according to the ASTME112 standard, the material texture is uniform and compact, the overall strength effect is excellent, and the high-pressure resistant characteristic is realized; the integral fatigue life of the gas cylinder reaches more than 15000 times, and the pressure bearing capacity completely meets the requirement of 20-30MPa service pressure.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the application and, together with the description, serve to explain the application and are not intended to limit the application. Wherein:
FIG. 1 is a schematic structural diagram of a high-pressure fully-wound gas cylinder with an aluminum alloy inner container with one end sealed according to some embodiments of the application;
FIG. 2 is a schematic flow chart of a method for manufacturing a high-pressure fully-wrapped gas cylinder with a bottom-sealed aluminum alloy liner according to some embodiments of the present application;
FIG. 3 is a schematic flow diagram illustrating the fabrication of an aluminum alloy liner piezotube provided in accordance with some embodiments of the present application;
fig. 4 is a schematic flow diagram of a process for grinding a screwed pipe of an aluminum alloy liner according to some embodiments of the present application;
FIG. 5 is a schematic flow diagram of a closing head spinning process provided in accordance with some embodiments of the present application;
FIG. 6 is a schematic flow diagram of a toric surface finish provided according to some embodiments of the present application;
fig. 7 is a schematic flow diagram of a heat treatment of a third spun piece provided according to some embodiments of the present application;
FIG. 8 is a schematic flow diagram of finish processing provided in accordance with some embodiments of the present application;
fig. 9 is a schematic flow diagram of liner cleaning provided in accordance with some embodiments of the present application;
figure 10 is a schematic flow diagram of liner pretreatment provided in accordance with some embodiments of the present application;
FIG. 11 is a schematic flow diagram of carbon fiber winding provided in accordance with some embodiments of the present application;
FIG. 12 is a schematic flow diagram of glass fiber winding provided in accordance with some embodiments of the present application;
fig. 13 is a schematic flow chart of step S14 provided according to some embodiments of the present application;
fig. 14 is a schematic flow chart of step S15 provided according to some embodiments of the present application;
fig. 15 is a schematic flow diagram of an aluminum alloy liner airtightness test provided in accordance with some embodiments of the present application.
Description of reference numerals:
100-aluminum alloy inner container; 200-a composite reinforcement layer; 300-outer protective layer.
Detailed Description
The present application will be described in detail below with reference to the embodiments with reference to the attached drawings. The various examples are provided by way of explanation of the application and are not limiting of the application. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present application without departing from the scope or spirit of the application. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. It is therefore intended that the present application cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
FIG. 1 is a schematic structural diagram of a high-pressure fully-wound gas cylinder with an aluminum alloy inner container with one end sealed according to some embodiments of the application; as shown in fig. 1, the aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed comprises: the aluminum alloy liner 100, the composite material reinforcing layer 200 and the outer protective layer 300; the shown aluminum alloy inner bag 100 is the seamless structure of the integral type of one end back cover, other end binding off shaping head and bottleneck, includes: the bottle comprises a bottle mouth, a sealing head, a straight cylinder section and a back cover, wherein the sealing head and the back cover are respectively positioned at two ends of the straight cylinder section, and the bottle mouth is positioned on the sealing head and the back cover; the length of the aluminum alloy inner container is less than 5 meters, the nominal outer diameter of the straight cylinder section is phi 406-phi 850mm, and the rated pressure of the high-pressure gas cylinder is 20-30 Mpa; the method comprises the following steps of preparing a seamless pipe consisting of a sealed bottom and a straight cylinder section with an opening at one end by adopting reverse extrusion forming, carrying out multi-pass strong external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control strong external spinning press to obtain an aluminum alloy liner 100 spinning pipe, and carrying out scratch and collision grinding on the inner and outer surfaces of the aluminum alloy liner 100 spinning pipe with surface defects detected by adopting a numerical control internal and external grinding machine after the fixed-length processing, cleaning and defect inspection of the aluminum alloy liner 100 spinning pipe; when the aluminum alloy liner 100 spinning tube is polished, the aluminum alloy liner 100 spinning tube is driven to rotate, the inner circle polishing mechanism is driven to carry out positioning on the detected inner surface defects through visual detection equipment, and point-by-point polishing is carried out according to the positioned positions; during grinding, the 100-degree rotating-pressing pipe of the aluminum alloy inner container swings within an angle range of (-10 degrees and 10 degrees) at the speed of 30 r/min; driving the 100 spinning pipe of the aluminum alloy inner container to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the detected outer surface defects, and continuously grinding according to the positioned position; the composite material reinforcing layer 200 is coated on the outer side of the aluminum alloy inner container 100, wherein the composite material reinforcing layer 200 is formed by winding carbon fibers in a spiral and annular combined winding mode and curing resin; the outer protective layer 300 is wrapped on the outer side of the composite material reinforcing layer 200, wherein the outer protective layer 300 is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin.
In the embodiment of the application, the length of the gas cylinder is not more than 5m, the nominal outer diameter is (406, 850) mm, and the working pressure is (20, 30) MPa; the volume of the gas cylinder is (280, 2800) L; preferably, the length of the gas cylinder is (2.8, 5) m; the working pressure of the gas cylinder is 20 MPa; the volume of the gas cylinder is (280, 510) L; the service temperature of the gas cylinder is (-40 ℃, 85 ℃); the gas cylinder is used for containing CNG gas and high-purity industrial gas; the gas cylinder is used for vehicle-mounted horizontally-placed fuel gas cylinders and vertical-type vehicle-mounted storage and transportation gas cylinders.
In the embodiment of the application, the wall thickness of the straight cylinder section of the aluminum alloy liner 100 is (1, 10) mm, and the integral straightness of the straight cylinder section is not more than 0.5 mm/m; preferably, the tolerance of the wall thickness of the straight cylinder section is less than or equal to +/-0.15 mm; the local straightness at any straight line section position of the straight cylinder section is not more than 0.5mm/300 mm; the roundness of any position of the straight cylinder section is not more than 0.5 mm; the roughness of the inner surface of the straight cylinder section is less than Ra1.6 mu m, and the roughness of the outer surface of the straight cylinder section is less than Ra3.2 mu m.
In the embodiment of the application, the thickness of the seal head is uniformly gradually thickened from the edge to the bottle mouth; preferably, the thickness of the end socket is uniformly and gradually thickened from (5,8) mm at the edge to (10,25) mm at the bottle opening part; the thickness of the back cover is uniformly and gradually thickened from (5,8) mm at the edge to (10,25) mm at the bottom of the back cover; the end socket can adopt an ellipsoidal end socket, a butterfly end socket or a hemispherical end socket, and the structural type of the end socket is the same as the structural type of the curved surface of the end socket; the thickness of the back cover is uniformly and gradually thickened from the edge to the center of the back cover; the end socket can adopt an ellipsoidal end socket, a butterfly end socket or a hemispherical end socket, and the structure of the end socket is the same as that of the end socket; preferably, the length of the bottle mouth is 40mm, the outer diameter of the bottle mouth is 50mm, and the inner diameter of the bottle mouth is 28 mm.
In the embodiment of the present application, the carbon fibers of the composite reinforcement layer 200 and the glass fibers of the outer protective layer 300 are both wound by a wet process; preferably, the carbon fibers are continuous untwisted carbon fibers; the tensile strength of the carbon fiber is not less than 4300 MPa; the winding tension of carbon fiber winding is not less than 5N; the resin is thermosetting resin, and the glass transition temperature of the resin is not lower than 105 ℃; preferably, the resin is an epoxy resin or a modified epoxy resin; and (3) curing the carbon fiber and/or the glass fiber by using a box-type heating furnace within 4 hours after the carbon fiber and/or the glass fiber are wound, wherein the gas cylinder rotates automatically all the time during curing.
In the embodiment of the application, the gas cylinder needs to be subjected to self-tightening water pressure, water pressure and air tightness tests, fatigue tests and explosion tests; preferably, the self-tightening hydraulic pressure is 1.8 times of the use pressure of the gas cylinder; the fatigue times of the gas cylinder fatigue test are not less than 15000 times.
FIG. 2 is a schematic flow chart of a method for manufacturing a high-pressure fully-wrapped gas cylinder with a bottom-sealed aluminum alloy liner according to some embodiments of the present application; as shown in fig. 2, the method for manufacturing the aluminum alloy liner 100 high-pressure fully-wound gas cylinder is used for manufacturing the aluminum alloy liner 100 high-pressure fully-wound gas cylinder according to any one of the embodiments, and comprises the following steps:
step S1, carrying out integral reverse extrusion forming on the blank with the back cover;
the step S1: adopting a heating backward extrusion process combined with turning and boring processes to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end; the method specifically comprises the following steps:
heating an aluminum ingot, and preheating the aluminum ingot to be extruded to 200-400 ℃;
heating the mold, and preheating the outer extrusion mold and the inner extrusion rod to 200-400 ℃;
extrusion molding, namely placing an aluminum ingot in an extrusion die, and extruding the blank for multiple times into a prefabricated pipe blank with a bottom seal under the condition of continuous heating and temperature preservation;
processing the outer surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a turning method;
processing the inner surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a boring method to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end;
step S2, preparing an aluminum alloy inner container spinning pipe: carrying out multi-pass powerful external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control powerful external spinning machine to obtain an aluminum alloy inner container spinning pipe;
FIG. 3 is a schematic flow diagram illustrating the fabrication of an aluminum alloy liner piezotube provided in accordance with some embodiments of the present application; as shown in fig. 3, the process of preparing the aluminum alloy liner spinning tube comprises the following steps:
step S201, spinning and forming a straight cylinder section of the aluminum alloy liner spinning pipe: carrying out 2-4 times of spinning process on the seamless pipe by adopting a three-wheel staggered forward spinning or backward spinning method to obtain a first spinning piece (spinning piece A); when in forward spinning, a core mould with the processing length equal to 1.2-1.4 times of the length of a set product is adopted for spinning auxiliary processing; during reverse spinning, a core mold with the processing length equal to 0.6-0.8 time of the length of a set product is adopted for spinning auxiliary processing;
in the embodiment of the application, the offset in the three-wheel offset forward spinning or reverse spinning method is set to be 6-12 mm; the equipment used in the three-wheel offset forward spinning or reverse spinning method is full-automatic spinning equipment with functions of automatic grease spraying, automatic feeding and discharging and automatic spinning pressure detection.
Step S202, fixed-length processing of the aluminum alloy liner spinning pipe: performing fixed-length processing on the first spinning piece (spinning piece A) obtained in the step S201 to obtain an aluminum alloy liner spinning tube;
step S203, cleaning the aluminum alloy inner container spinning pipe: cleaning the aluminum alloy inner container spinning pipe obtained in the step S202 by using a cleaning machine;
in the embodiment of the application, the cleaning machine is a rotary spray cleaning machine or an ultrasonic cleaning machine; cleaning the aluminum alloy inner container spinning pipe by using a neutral cleaning agent heated to 30-45 ℃; and (3) removing residual water stains on the surface by using a special wiping tool or a drying device after cleaning the aluminum alloy inner container spinning tube.
Step S204, checking the aluminum alloy inner container spinning pipe: inspecting the shape and size tolerance of the aluminum alloy liner spinning tube by adopting size, shape tolerance and surface defect detection equipment, and automatically detecting whether the inner surface and the outer surface have defects;
in the embodiment of the application, the surface defect detection equipment is spinning tube laser vision automatic detection equipment; the surface defect detection equipment automatically detects whether the inner surface and the outer surface of the aluminum alloy liner spinning tube are scratched or not.
Step S205, grinding the aluminum alloy inner container spinning tube: grinding the scratch and the bruise of the inner surface and the outer surface of the aluminum alloy liner spinning tube with the surface defect detected in the step S204 by using a numerical control inner and outer circle grinding machine;
in the embodiment of the application, the numerical control inner and outer circle grinding machine has a visual rechecking function so as to grind scratches and bruises on the inner surface and the outer surface of the aluminum alloy inner container spinning tube with surface defects detected.
Fig. 4 is a schematic flow diagram of a process for grinding a screwed pipe of an aluminum alloy liner according to some embodiments of the present application; as shown in fig. 4, the grinding aluminum alloy liner spinning tube comprises:
s215, driving the aluminum alloy liner spinning pipe to rotate, driving a visual detection device of the inner circle grinding mechanism to position the inner surface defects detected in the step S204, and grinding point by point according to the positioned position; during grinding, the aluminum alloy liner spinning pipe swings at the speed of 30r/min within the angle range of (-10 degrees and 10 degrees);
s225, driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the outer surface defect detected in the step S104, and continuously grinding according to the positioned position;
step S206, carrying out full-automatic flaw detection on the straight cylinder section of the aluminum alloy liner spinning pipe obtained in the step S205 by using a special ultrasonic automatic flaw detector, and detecting whether a processing defect exists;
in the embodiment of the application, the special ultrasonic automatic flaw detector performs full-automatic flaw detection on the straight cylinder section of the aluminum alloy liner spinning tube, and detects whether the straight cylinder section of the aluminum alloy liner spinning tube has peeling, wrinkles and cracks.
Step S3, closing the end socket and spinning and forming the bottle mouth: adopting a heating closing-up spinning machine to spin-form the opening of the aluminum alloy liner spinning tube with the end socket and the bottle mouth to obtain a second spinning piece (spinning formed piece B),
FIG. 5 is a schematic flow diagram of a closing head spinning process provided in accordance with some embodiments of the present application; as shown in fig. 5, the flow of spinning formation of the closing end includes:
step S301, clamping: clamping the aluminum alloy inner container spinning pipe by adopting a split type hollow main shaft;
step S302, heating: heating the spinning part of the spinning pipe of the aluminum alloy inner container to be contracted to 200-400 ℃;
in the embodiment of the application, oxygen and propane/LNG natural gas are used for combustion flame spraying heating when the spinning part to be closed of the aluminum alloy inner container spinning tube is heated;
step S303, forming and spinning of the end socket and the bottle mouth: performing multi-pass necking spinning on the aluminum alloy liner spinning tube heated in the step S302 by adopting a unilateral X straight line, a unilateral Z straight line and a rotary three-way interpolation type necking spinning machine; wherein, in the spinning process, the closing spinning band has 4 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared second spinning part (spinning forming part B) is uniformly and gradually thickened from 6mm of the edge to 25mm of the bottle opening part;
step S304, repeating the operations of the steps S301, S302 and S303 on the other end of the spinning pipe of the aluminum alloy liner to obtain a second spinning part (spinning formed part B); the second spinning part (spinning forming part B) comprises a straight cylinder section, and end enclosures and back enclosures at two ends of the straight cylinder section;
step S305, a center hole of the on-position bottle opening is processed on the second spinning member (spinning formed part B) in step S304.
In the embodiment of the application, the center hole of the on-site bottle mouth is machined by multi-shaft automatic machining.
Step S4, processing of a central hole and an excircle of a bottle mouth: machining a center hole and an outer circle of a bottle opening of the second spinning part (spinning formed part B) obtained in the step S3, and machining the outer circle of the mounting column of the back cover to obtain a third spinning part (spinning formed part C);
step S5, curved surface flaw detection: performing closing quality flaw detection on the third spinning part (spinning formed part C) obtained in the step S4, and checking whether machining defects such as orange peel and folding exist at the end socket position;
step S6, grinding the inner surface of the curved surface: grinding the defects of the inner surface of the end socket found in the step S5 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third spinning part (spinning formed part C) with qualified quality;
FIG. 6 is a schematic flow diagram of a toric surface finish provided according to some embodiments of the present application; as shown in fig. 6, the process of thinning the curved inner surface includes:
step S601, clamping a third spinning part (spinning formed part C) by using a special clamping tool;
in the embodiment of the application, the clamping tool of the third spinning part (spinning formed part C) is a split hollow clamping tool;
step S602, automatically observing and judging the defect condition of the inner surface of the end socket by adopting an automatic endoscope system arranged on a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S603, grinding the defects of the inner surface of the end socket found in the step S5 by using an inner surface grinding mechanism of the end socket of the special end socket inner surface grinding machine tool to obtain a third spinning part (spinning formed part C) with qualified quality.
In the embodiment of the application, the grinding of the inner profile of the end socket is a numerical control automatic grinding mechanism which can be programmed and executed independently.
Step S7, heat treatment: performing T6 process treatment on the third spinning part (spinning formed part C) obtained in the step S6 to obtain an aluminum alloy inner container blank for the high-pressure gas cylinder;
fig. 7 is a schematic flow diagram of a heat treatment of a third spun piece provided according to some embodiments of the present application; as shown in fig. 7, the flow of the heat treatment of the third spinning member includes:
step S701, quenching: putting the third spinning part (spinning formed part C) prepared in the step S6 into a quenching furnace for quenching treatment, heating the third spinning part (spinning formed part C) to 525-;
in the embodiment of the application, the quenching furnace is a vertical aluminum alloy box-type quenching furnace or a through-type continuous quenching furnace.
Step S702, aging treatment: transferring the quenched third spinning part (spinning formed part C) to an aging furnace for aging treatment, and finally preserving heat for 6-10 hours in an environment with the temperature of 160-200 ℃ to prepare the aluminum alloy liner blank for the high-pressure gas cylinder.
In the embodiment of the application, the aging furnace is a trolley type aluminum alloy aging furnace or a through type continuous aging furnace.
Step S8, processing bottle mouth: machining the inner diameter and the outer diameter of the opening of the aluminum alloy liner blank for the high-pressure gas cylinder obtained in the step S7 respectively by using a special opening machining center, machining an inner thread and an outer thread of the opening, and machining an outer thread of the bottom-sealed mounting column to obtain an aluminum alloy liner 100 for the high-pressure gas cylinder;
FIG. 8 is a schematic flow diagram of finish processing provided in accordance with some embodiments of the present application; as shown in fig. 8, the process of bottle mouth processing includes:
step S801, clamping an aluminum alloy inner container blank by adopting a split type hollow clamping tool;
step S802, processing a bottle mouth: and (4) processing the outside diameter and the inside diameter of the bottle mouth of the aluminum alloy inner container blank obtained in the step (S6) and the inside and outside threads of the bottle mouth by using a special bottle mouth processing center to obtain the aluminum alloy inner container 100 for the high-pressure gas bottle, wherein the length, the outside diameter and the inside diameter of the bottle mouth are respectively 40mm, 50mm and 28 mm.
Step S9, inner container cleaning: performing high-pressure water spraying cleaning on the inner cavity of the aluminum alloy liner for the oversized high-pressure gas cylinder obtained in the step S8 by using a special horizontal gas cylinder liner cleaning machine to remove aluminum scraps and other processing pollutants, and drying;
fig. 9 is a schematic flow diagram of liner cleaning provided in accordance with some embodiments of the present application; as shown in fig. 9, the cleaning of the aluminum alloy liner comprises:
step 901, vertically placing the aluminum alloy liner 100 on a special vertical gas cylinder liner cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder liner cleaning machine to enter the aluminum alloy liner 100, and fixing the aluminum alloy liner 100;
step S902, cleaning the inner cavity of the aluminum alloy inner container 100 by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove processing pollutants;
step S903, after the cleaning is finished, starting the turnover frame to incline to 45 degrees, enabling the end sealing end to face downwards, and pouring water;
and step S904, drying the liner by adopting an inward extending type steam dryer.
Step S10, checking the semi-finished product: performing sampling inspection on the aluminum alloy inner container obtained in the step S9, measuring the texture grain sizes of any six positions of the aluminum alloy inner container subjected to sampling inspection, and measuring the tensile strength, yield strength and elongation of the straight cylinder section of the aluminum alloy inner container subjected to sampling inspection; wherein the tensile strength of the straight cylinder section of the aluminum alloy liner is not less than 345MPa, the yield strength is not less than 310MPa, and the elongation is less than 16%;
step S11, preprocessing the inner container: horizontally placing the aluminum alloy inner container 100 in the step S9 on a coating station of special automatic coating and drying equipment by adopting special automatic coating and drying equipment, and coating the aluminum alloy inner container with an anti-galvanic corrosion layer;
figure 10 is a schematic flow diagram of liner pretreatment provided in accordance with some embodiments of the present application; as shown in fig. 10, the liner pretreatment includes:
step S1101, preparing a glue solution according to a weight ratio of resin to curing agent of 1: 0.85;
in the embodiment of the application, the galvanic corrosion prevention layer adopts the mixed liquid of epoxy resin and curing agent.
Step S1102, recording the serial number of the aluminum alloy liner 100, measuring the weight of the aluminum alloy liner 100 by using an electronic balance, winding the same thread by using a winding tool, sleeving tetrafluoro gaskets on the thread positions of the winding tool, screwing the tetrafluoro gaskets to bottle mouths at two ends of the aluminum alloy liner 100, and fixing the aluminum alloy liner 100 on a coating device;
step S1103, automatically coating glue solution by adopting an automatic coating rolling brush until the glue solution is uniformly coated on the aluminum alloy inner container 100;
and S1104, curing the aluminum alloy inner container in a rotary curing mode at the curing temperature of 160 ℃ for 2 hours.
In the embodiment of the application, the drying temperature of the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer is 140-.
Step S12, carbon fiber winding: performing carbon fiber winding processing on the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer in the step S11 by using a numerical control automatic winding machine;
FIG. 11 is a schematic flow diagram of carbon fiber winding provided in accordance with some embodiments of the present application; as shown in fig. 11, the flow of carbon fiber winding includes:
step S1201, mounting a bottle mouth outer sleeve at the bottle mouth, and checking the smooth degree of the transition between the bottle mouth outer sleeve and the end socket curved surface section; leading out carbon fiber yarns from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarns on the winding nozzle to finish threading;
step S1202, mixing epoxy resin and a curing agent according to a certain proportion, pouring the prepared glue solution into a glue dipping tank, opening a heating button of the glue dipping tank, and setting the glue dipping tank to a specified temperature;
step S1203, installing two end winding fixing tools on the weighed aluminum alloy inner container 100 for the high-pressure gas cylinder and fixing the tools on a winding machine;
step S1204, selecting a winding program, unwinding the yarn tied at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the gas cylinder until the yarn soaked with the resin is pulled onto the inner container, and starting and finishing carbon fiber winding.
Step S13, winding glass fiber: carrying out glass fiber winding processing on the semi-finished product of the gas cylinder with the layers of carbon fibers wound in the step S11 by adopting a numerical control automatic winding machine;
FIG. 12 is a schematic flow diagram of glass fiber winding provided in accordance with some embodiments of the present application; as shown in fig. 12, the glass fiber winding process includes:
step S1301, mounting two end winding fixing tools on the semi-finished product of the gas cylinder wound with the carbon fibers obtained in the step S12, and fixing the semi-finished product of the gas cylinder on a winding machine;
step S1302, pasting two labels with the same number on two sides of the middle part of the gas cylinder;
step S1303, leading out the glass fiber yarn from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarn on the winding nozzle to finish yarn threading;
step S1304, pouring the mixed epoxy resin and the curing agent according to the proportion, pouring the prepared glue solution into a glue dipping tank, opening a heating button of the glue dipping tank, and setting the glue solution to a specified temperature;
step S1305, selecting a winding program, unwinding the yarn at the yarn winding nozzle, manually winding the yarn on the aluminum alloy inner container, ensuring that the yarn and the aluminum alloy inner container do not slip, rotating the gas cylinder until the yarn soaked with resin is pulled onto the inner container, and starting and finishing glass fiber winding according to set tension; wherein, the thickness of the single layer is 0.464mm, the circumferential winding angle is +/-89 degrees, and the longitudinal winding angle is +/-5 degrees.
Step S14, curing: a box-type heating furnace with the function of supporting the gas cylinder to automatically rotate in the furnace is adopted for curing the gas cylinder, and a stepped temperature rise and fall curve is adopted for curing;
fig. 13 is a schematic flow chart of step S14 provided according to some embodiments of the present application; as shown in fig. 13, step S14 includes:
step S1401, placing a winding gas cylinder on a box type heating furnace support frame, and fixing a rotary joint of the box type heating furnace and a winding tool through a positioning pin;
step S1402, the equipment is called into a program model, and a starting key is turned on for curing after a programmed curing program is selected according to the set heating temperature and the set heat preservation time;
and step S1403, after solidification is finished, opening a box type heating furnace to cool, opening an equipment door after the temperature is reduced to a specified value, and moving the solidified gas cylinder to the next procedure.
Preferably, the solidified gas cylinder is transferred by a special lifting device capable of lifting two-end winding tools.
Step S15, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests of the gas cylinder one by one;
fig. 14 is a schematic flow chart of step S15 provided according to some embodiments of the present application; as shown in fig. 14, step S15 includes:
step S1501, connecting the tested gas bottle with a hydrostatic testing machine through a hydrostatic joint after the tested gas bottle is filled with water, wherein the connecting pipeline is free of gas;
step S1502, carrying out self-tightening water pressure on the tested gas cylinder at room temperature, wherein the self-tightening water pressure is 1.8 times of the use pressure, the boosting rate does not exceed 0.5MPa/S in the boosting process, and after the pressure is reached, maintaining the pressure for 5min under the self-tightening water pressure, and then releasing the pressure;
step S1503, carrying out hydrostatic test on the tested gas cylinder at room temperature, wherein the pressure is 1.5 times of the use pressure, the boosting rate does not exceed 0.5MPa/S in the boosting process, the pressure is maintained for 30S after the pressure reaches, and then the pressure is released; wherein the volume residual deformation rate of the tested gas cylinder is not more than 5%.
Step S16, airtight test: carrying out air tightness leakage detection tests on the air cylinders one by adopting an integrated air tightness testing machine with an explosion-proof function;
FIG. 15 is a schematic flow diagram of an aluminum alloy liner airtightness test provided in accordance with some embodiments of the present application; as shown in fig. 15, step S16 includes:
s1601, placing a tested gas bottle in an airtight test box, immersing the gas bottle in water, and connecting a test pipeline;
and S1602, performing a water immersion method airtight test, wherein the test pressure is (0, 20) MPa, the test temperature is room temperature, the test medium is compressed air, maintaining the pressure for 1min under the test pressure, and observing whether bubbles appear in the pressure maintaining process through a high-definition camera.
In the embodiment of the application, the methods adopted in the airtight leakage detection test comprise a liquid coating method, a water immersion method and a helium mass spectrum leakage detection method, and the airtight leakage detection test is carried out on the gas cylinders one by one; furthermore, a helium mass spectrometer leak detection method is adopted for a hydrogen cylinder product to carry out a gas tightness leak detection test.
Step S17, fatigue test: performing sampling inspection verification on the fatigue performance of the gas cylinder by adopting a fatigue pressure cycle tester according to the proportion of one gas cylinder in each batch;
in the embodiment of the application, in the fatigue test process, the test pressure is (0, 21) MPa, the test temperature is room temperature, the test medium is oil or water, the pressure cycle is carried out for at least 15000 times from 0MPa to 21MPa, and the body of the tested gas cylinder does not leak or explode.
Step S18, blasting test: and (4) performing sampling inspection verification on the blasting performance of the gas cylinders by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch.
In the embodiment of the application, during the burst test, the pressure of the tested gas cylinder is increased to 45MPa by adopting an aqueous medium, and after the pressure is maintained for 5s, the pressure is continuously increased until the tested gas cylinder is damaged.
In the embodiment of the application, a composite processing method such as spinning, winding and curing is adopted to manufacture the aluminum alloy liner 100 with the integrated seamless structure and the end socket and the bottle mouth formed by closing up two ends, carbon fibers are wound on the outer side of the aluminum alloy liner 100 in a spiral and annular combined winding mode and are cured by resin to form the composite material reinforcing layer 200 covering the aluminum alloy liner 100; on the outside of the composite reinforcement layer 200, glass fiber is wound in a combined spiral and hoop winding manner and cured with resin to form an outer protective layer 300 covering the composite reinforcement layer 200. The whole manufacturing process has the advantages of simple preparation process, convenient operation, low energy consumption, little pollution and less raw material loss, and greatly saves the raw material cost; meanwhile, because one end is provided with the back cover, the length of the gas cylinder is reduced, and the gas storage capacity is increased.
According to the manufacturing method of the aluminum alloy inner container 100 high-pressure fully-wound gas cylinder provided by the embodiment of the application, the processed aluminum alloy inner container 100 high-pressure fully-wound gas cylinder has the nominal outer diameter of phi 406-phi 850mm and the volume far higher than that of the existing standard aluminum alloy inner container 100 high-pressure fully-wound gas cylinder; the grain size of the texture at any position of the aluminum alloy inner container 100 is more than or equal to 5 grade according to the ASTME112 standard, the texture of the material is uniform and compact, the overall strength effect is excellent, and the high-pressure resistant characteristic is realized; the integral fatigue life of the gas cylinder reaches more than 15000 times, and the pressure bearing capacity completely meets the requirement of 20-30MPa service pressure.
Example 1
In the embodiment of the application, the aluminum alloy liner 100 for the high-pressure gas cylinder with the diameter of 420mm, the length of 2.5m and the wall thickness of 4mm is manufactured by the manufacturing method of the aluminum alloy liner high-pressure fully-wound gas cylinder with one end sealed, wherein the rated pressure of the high-pressure gas cylinder is required to be 25Mpa, and the method comprises the following specific steps:
step S1, carrying out integral reverse extrusion forming on the blank with the back cover;
the step S1: adopting a heating backward extrusion process combined with turning and boring processes to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end; the method specifically comprises the following steps:
heating an aluminum ingot, and preheating the aluminum ingot to be extruded to 200-400 ℃;
heating the mold, and preheating the outer extrusion mold and the inner extrusion rod to 200-400 ℃;
extrusion molding, namely placing an aluminum ingot in an extrusion die, and extruding the blank for multiple times into a prefabricated pipe blank with a bottom seal under the condition of continuous heating and temperature preservation;
processing the outer surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a turning method;
processing the inner surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a boring method to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end;
step S2, preparing an aluminum alloy inner container spinning tube, comprising the following steps: and (3) carrying out multi-pass powerful external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control powerful external spinning machine to obtain the aluminum alloy inner container spinning pipe.
Step S201, spinning forming of the straight cylinder section of the aluminum alloy liner spinning pipe,
2-pass spinning is carried out on the seamless pipe with the length of 1m by adopting a three-wheel offset forward spinning method, and the offset in the three-wheel offset forward spinning method is set to be 6 mm; obtaining a first spinning and pressing piece (spinning and pressing piece A), wherein the first spinning and pressing piece (spinning and pressing piece A) is a straight cylinder with equal thickness or a straight cylinder section with two ends provided with outer annular end frames; the dimensions of the first rotary pressing member (rotary pressing member a) are: the total length is 3000mm, the thickness of straight section of thick bamboo is 4mm, and both ends step section thickness is 10 mm.
Step S202, fixed-length processing of the aluminum alloy liner spinning pipe: performing fixed-length processing on the first spinning part (spinning part A) obtained in the step S201 by using a double-column automatic sawing machine to obtain an aluminum alloy inner container spinning pipe, wherein the length of a straight cylinder section of the aluminum alloy inner container spinning pipe is 2600 mm;
step S203, cleaning the aluminum alloy inner container spinning pipe: adding a neutral cleaning agent at 40 ℃ into a rotary spray cleaning machine or an ultrasonic cleaning machine to clean the aluminum alloy liner rotary pressure pipe obtained in the step S202; and after cleaning, removing residual water stains on the surface by using an automatic wiping machine or a drying device.
S204, adopting automatic laser visual detection equipment for the spinning tube, fixing the spinning tube of the aluminum alloy liner obtained in the step S203 on a lathe bed through an automatic clamping device, and carrying out quality detection on the spinning tube;
in the embodiment of the present application, the flow of step S204 is specifically as follows:
s214, programming and rotating the aluminum alloy liner spinning tube, and driving a laser detection mechanism to automatically detect whether the dimensions such as the diameter, the roundness, the straightness, the end face verticality and the like of the aluminum alloy liner spinning tube and the form and position tolerance meet the design requirements;
s224, programming to rotate the aluminum alloy liner spinning tube, and driving the inner surface visual recognition device to automatically detect whether the inner surface has surface defects such as scratches, peeling, folds, surface cracks and the like with the depth of more than 0.1 mm;
and 234, programming to rotate the aluminum alloy liner spinning pipe, driving the outer surface visual identification device, and automatically detecting whether the inner surface has surface defects such as scratches, peeling, wrinkles, surface cracks and the like with the depth of more than 0.1 mm.
Step S205, grinding the aluminum alloy inner container spinning tube: fixing the aluminum alloy liner spinning tube with the surface defects detected in the step S204 on a numerical control inner and outer circle grinding machine through an automatic clamping device, and grinding the inner and outer surfaces of the cleaned aluminum alloy liner spinning tube detected in the step S204 by scratching and bruising;
in the embodiment of the present application, the flow of step S205 is specifically as follows:
step S215, driving the aluminum alloy liner spinning tube to rotate, firstly driving a visual detection device of the inner circle grinding mechanism to position the inner surface defect detected in the step S204, and grinding point by point according to the positioned position, wherein the aluminum alloy liner spinning tube swings in an angle range of-10 degrees to +10 degrees at the speed of 30r/min during grinding;
and step S225, driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the outer surface defect detected in the step S204, and carrying out continuous grinding according to the positioned position.
And S206, carrying out full-automatic flaw detection on the aluminum alloy inner container spinning tube obtained in the step S205 by using an ultrasonic automatic flaw detector, and detecting whether the barrel has machining defects such as orange peel and folding.
Step S3, closing the end socket and spinning and forming the bottle mouth: carrying out spin forming on the end socket and the bottle mouth at the opening of the aluminum alloy liner spin-pressing pipe by using a heating closing-up spinning machine to obtain a second spin-pressing part (spin-formed part B);
specifically, step S2 includes:
step S301, clamping: clamping the aluminum alloy inner container spinning pipe by adopting a split type hollow main shaft;
step S302, heating: carrying out flame spraying and heating on a spinning part to be closed of the spinning pipe of the aluminum alloy liner to 310 ℃ by adopting oxygen and propane/LNG natural gas combustion;
step S303, forming and spinning of the end socket and the bottle mouth: performing closing-up spinning on the aluminum alloy liner spinning tube heated in the step S302 by adopting a unilateral X-line, Z-line and rotary three-way interpolation type closing-up spinning machine;
in the spinning process, the closing spinning band has 4 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared second spinning part (spinning forming part B) is uniformly and gradually thickened from 6mm of the edge to 20mm of the bottle opening part.
And S304, repeating the operations of the steps S301, S302 and S303 on the other end of the spinning pipe of the aluminum alloy liner to obtain a second spinning piece (spinning formed piece B).
Step S4, processing of a central hole and an excircle of a bottle mouth: clamping a second spinning part (spinning formed part B) by adopting a split type hollow clamping tool, machining a center hole and an excircle of a bottle mouth of the second spinning part (spinning formed part B) obtained in the step S3 by adopting a special bottle mouth machining center, and machining the excircle of the mounting column of the back cover to obtain a third spinning part (spinning formed part C); preparing for subsequent heat treatment;
step S5, curved surface flaw detection: performing closing quality flaw detection on the third spinning part (spinning formed part C) obtained in the step S4, and checking whether machining defects such as orange peel and folding exist at the end socket position;
step S6, grinding the inner surface of the curved surface: grinding the defects of the inner surface of the end socket found in the step S5 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third spinning part (spinning formed part C) with qualified quality;
specifically, step S6 includes:
step S601, clamping a third spinning part (spinning formed part C) by adopting a split type hollow clamping tool;
step S602, automatically observing and judging the defect condition of the inner surface of the end socket by adopting a visual recognition system of a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S603, grinding the defects of the inner surface of the end socket found in the step S5 by using a numerical control automatic grinding mechanism of a special end socket inner surface grinding machine tool to obtain a third spinning part (spinning formed part C) with qualified quality, wherein the numerical control automatic grinding mechanism can be programmed and independently executed in the grinding process.
Step S7, heat treatment: performing T6 process treatment on the third spinning part (spinning formed part C) obtained in the step S6 to obtain an aluminum alloy inner container blank for the high-pressure gas cylinder;
specifically, step S7 includes:
step S701, quenching: putting the third spinning part (spinning formed part C) prepared in the step S6 into a vertical aluminum alloy box type quenching furnace for quenching treatment, heating the third spinning part (spinning formed part C) to 525-;
step S702, aging treatment: transferring the quenched third spinning part (spinning formed part C) to a trolley type aluminum alloy aging furnace for aging treatment, and finally preserving heat for 9 hours in an environment of 160 ℃ to prepare an aluminum alloy inner container blank for the high-pressure gas cylinder. In the whole quenching treatment and aging treatment processes, the aluminum alloy inner container blank for the high-pressure gas cylinder is vertically fixed in a special heat treatment material frame by adopting a special heat treatment tool.
Step S8, processing bottle mouth: machining the inner diameter and the outer diameter of the opening of the aluminum alloy liner blank for the high-pressure gas cylinder obtained in the step S7 respectively by using a special opening machining center, machining an inner thread and an outer thread of the opening, and machining an outer thread of the bottom-sealed mounting column to obtain an aluminum alloy liner 100 for the high-pressure gas cylinder;
specifically, step S8 includes:
step S801, clamping an aluminum alloy inner container blank for a high-pressure gas cylinder by adopting a split type hollow clamping tool;
step S802, processing a bottle mouth: and (4) carrying out high-speed processing on the outside diameter and the inside diameter of the bottle mouth and the inside thread of the bottle mouth of the aluminum alloy liner blank for the high-pressure gas bottle obtained in the step (S7) by using a special bottle mouth processing center to obtain the aluminum alloy liner 100 for the high-pressure gas bottle, wherein the length, the outside diameter and the inside diameter of the bottle mouth are respectively 40mm, 50mm and 28 mm.
Step S9, inner container cleaning: performing high-pressure water spraying cleaning on the inner cavity of the aluminum alloy liner for the oversized high-pressure gas cylinder obtained in the step S7 by using a special horizontal gas cylinder liner cleaning machine to remove aluminum scraps and other processing pollutants, and drying;
specifically, step S9 includes:
step 901, vertically placing the aluminum alloy inner container 100 for the high-pressure gas cylinder on a special vertical gas cylinder inner container cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder inner container cleaning machine to enter the inner container, and fixing the inner container;
step S902, cleaning the inner cavity of the aluminum alloy inner container 100 for the high-pressure gas cylinder by adopting high-pressure water spraying to remove aluminum scraps and other processing pollutants;
step S903, after the cleaning is finished, starting the turnover frame to incline to 45 degrees, enabling the end sealing end to face downwards, and pouring water;
and step S904, drying the liner by adopting an inward extending type steam dryer.
Step S10, checking the semi-finished product: the aluminum alloy inner container 100 for the high-pressure gas cylinder obtained in step S9 is inspected, and a part of items are subjected to spot inspection at a spot inspection rate of 1 piece per batch (usually, the number of pieces per batch is not more than 200 pieces). The texture grain sizes of any six positions of the aluminum alloy inner container 100 for the high-pressure gas cylinder to be inspected are measured, and the texture grain sizes of the six positions are respectively 6-grade, 7-grade, 6-grade and 5-grade according to the ASTM E112 standard, and the tensile strength of the straight cylinder section of the aluminum alloy inner container 100 for the high-pressure gas cylinder to be inspected is measured. And respectively measuring the yield strength and the elongation, wherein the tensile strength of the straight cylinder section is 345MPa, the yield strength is 310MPa, and the elongation is 16%, and the products produced in the batch are qualified, so that the finished product of the aluminum alloy liner 100 for the high-pressure gas cylinder is obtained.
Step S11, preprocessing the inner container: horizontally placing the aluminum alloy inner container 100 on a coating station of special automatic coating and drying equipment, and coating the aluminum alloy inner container with an anti-galvanic corrosion layer;
specifically, step S11 includes:
step S1101, preparing a glue solution according to a weight ratio of resin to curing agent of 1: 0.85;
step S1102, recording the serial number of the liner, measuring the weight of the liner by using an electronic balance, sleeving tetrafluoro gaskets on the thread positions of a winding tool by using the winding tool with the same threads, screwing the tetrafluoro gaskets to bottle mouths at two ends of the liner by hands, and fixing the liner on a coating device;
step S1103, automatically coating glue solution by adopting an automatic coating rolling brush until the glue solution is uniformly coated on the inner container;
step S1104, adopting a rotary curing mode, according to a curing temperature: 160 ℃, curing time: and curing the inner container within 2 h.
Step S13, carbon fiber winding: adopting a numerical control automatic winding machine to perform carbon fiber winding processing on the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer in the step S11
Specifically, step S12 includes:
step S1201, mounting a bottle mouth outer sleeve at the bottle mouth, and checking the smooth degree of the transition between the bottle mouth outer sleeve and the end socket curved surface section; leading out carbon fiber yarns from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarns on the winding nozzle to finish threading;
step S1202, according to epoxy resin: curing agent 1:0.85 (weight ratio) of mixed epoxy resin and curing agent, pouring the prepared glue solution into a glue dipping tank, wherein the glue content is 25%, opening a heating button of the glue dipping tank, and setting the temperature to a specified temperature;
step S1203, installing two end winding fixing tools on the coated aluminum alloy inner container 100 and fixing the two end winding fixing tools on a winding machine;
step S1204, selecting a winding program, unwinding the yarn tied at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the air bottle until the yarn soaked with resin is pulled on the inner container, setting the tension to be 5N, starting and finishing carbon fiber winding, wherein the thickness of a single layer of winding is 0.464mm, the annular winding angle is +/-89 degrees, and the longitudinal winding angle is +/-15 degrees.
Step S13, winding glass fiber: carrying out glass fiber winding processing on the semi-finished product of the gas cylinder with the layers of carbon fibers wound in the step S12 by adopting a numerical control automatic winding machine;
specifically, step S13 includes:
step S1301, mounting two end winding fixing tools on the semi-finished product of the gas cylinder wound with the carbon fibers obtained in the step S12 and fixing the semi-finished product on a winding machine;
step S1302, pasting two labels with the same number on two sides of the middle part of the gas cylinder;
step S1303, leading out the glass fiber yarn from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarn on the winding nozzle to finish yarn threading;
step S1304, pressing epoxy resin: curing agent 1:0.85 (weight ratio) of mixed epoxy resin and curing agent, pouring the prepared glue solution into a glue dipping tank, wherein the glue content is 40 percent, opening a heating button of the glue dipping tank, and setting the temperature to a specified temperature;
step S1305, selecting a winding program, unwinding the yarn at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the air bottle until the yarn soaked with resin is pulled on the inner container, setting the tension to be 5N, finishing the winding of 1 layer of circular glass fiber, wherein the thickness of a single layer of the winding is 0.464mm, and the circular winding angle is +/-89 degrees.
Step S14, curing: a box-type heating furnace with the function of supporting the gas cylinder to automatically rotate in the furnace is adopted for curing the gas cylinder, and a stepped temperature rise and fall curve is adopted for curing;
specifically, step S14 includes:
step S1401, a special lifting device capable of lifting winding tools at two ends is adopted to place a winding gas cylinder on a box type heating furnace support frame, and a rotary joint of the box type heating furnace is fixed with the winding tools through a positioning pin;
step S1402, the equipment is transferred into a program model, preheating and heating are set to 80 ℃, heat preservation is carried out for 1 hour, then heating is carried out to 120 ℃, heat preservation is carried out for 2 hours, and a starting key is opened for curing after a programmed curing program is selected;
and S1403, when the heat is preserved, automatically opening the cooling function of the box type heating furnace, cooling to 40 ℃, opening the equipment door, and moving the solidified gas cylinder to the next procedure.
Step S15, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests of the gas cylinder one by one;
specifically, step S15 includes:
and step S1501, connecting the tested bottle with a hydrostatic testing machine through a hydrostatic joint after the tested bottle is filled with water. No gas should be present in the pipeline;
step S1502, carrying out self-tightening water pressure on a tested bottle, wherein the self-tightening pressure is 1.8 times of the use pressure, namely 45Mpa, the boosting rate does not exceed 0.5MPa/S in the boosting process, keeping the pressure for 5min under the self-tightening pressure after the bottle is pressurized, and then releasing the pressure, wherein the test temperature is room temperature, and the test medium is water;
step S1503, carrying out a hydrostatic test on the tested bottle, wherein the pressure is 1.5 times of the use pressure, namely 37.5Mpa, the pressure increasing rate is not more than 0.5MPa/S in the pressure increasing process, the pressure is maintained for 30S after the pressure is reached, then the pressure is released, the test temperature is room temperature, the test medium is water, and the volume residual deformation rate is not more than 5%.
Step S16, airtight test: carrying out air tightness leakage detection tests on the air cylinders one by adopting an integrated air tightness testing machine with an explosion-proof function;
specifically, step S16 includes:
step S1601, placing a tested bottle in an airtight test box, immersing the tested bottle in water, and connecting a test pipeline;
and step S1602, performing a water immersion method airtight test, keeping the test pressure of 0-25 MPa and the test temperature at room temperature for 1min by using test medium compressed air, and observing by using a high-definition camera, wherein no bubbles are generated in the pressure keeping process.
Step S17, fatigue test: performing sampling inspection verification on the fatigue performance of the gas cylinder by adopting a fatigue pressure cycle tester according to the proportion of one gas cylinder in each batch;
the test pressure is 0MPa to 27MPa, the test temperature is room temperature, and the test medium oil or water is subjected to pressure cycle for at least 15000 times from 0MPa to 27 MPa; the bottle should not leak or burst.
Step S18, blasting test: and (4) performing sampling inspection verification on the blasting performance of the gas cylinders by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch. During the test, the gas cylinder is pressurized to 56.25MPa by adopting an aqueous medium, and after the pressure is maintained for 5s, the gas cylinder is not damaged and is qualified. Pressurization thereafter continues until failure.
Through inspection, the texture grain size of any position of the aluminum alloy inner container 100 for the high-pressure gas cylinder prepared in the embodiment is more than or equal to 5 grades according to the standard grade of ASTM E112, the tensile strength of the straight cylinder section is 345MPa, the yield strength is 310MPa, and the elongation is 16%; the testing limit pressure of the high-pressure gas cylinder obtained after the inner container is wound is 65Mpa, and the requirement of the rated pressure of 25Mpa is met.
Example 2
In the embodiment of the application, the aluminum alloy liner 100 for the high-pressure gas cylinder with the diameter of 618mm, the length of 4.5m and the wall thickness of 6mm is manufactured by the manufacturing method of the aluminum alloy liner high-pressure fully-wound gas cylinder with one end sealed, the rated pressure of the high-pressure gas cylinder is required to be 25Mpa, and the method comprises the following specific steps:
step S1, carrying out integral reverse extrusion forming on the blank with the back cover;
the step S1: adopting a heating backward extrusion process combined with turning and boring processes to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end; the method specifically comprises the following steps:
heating an aluminum ingot, and preheating the aluminum ingot to be extruded to 200-400 ℃;
heating the mold, and preheating the outer extrusion mold and the inner extrusion rod to 200-400 ℃;
extrusion molding, namely placing an aluminum ingot in an extrusion die, and extruding the blank for multiple times into a prefabricated pipe blank with a bottom seal under the condition of continuous heating and temperature preservation;
processing the outer surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a turning method;
processing the inner surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a boring method to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end;
s2, preparing an aluminum alloy inner container spinning pipe; and (3) carrying out multi-pass powerful external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control powerful external spinning machine to obtain the aluminum alloy inner container spinning pipe.
Specifically, step S2 includes:
step S201, spinning forming of the straight cylinder section of the aluminum alloy liner spinning pipe: 3-pass spinning is carried out on the seamless pipe with the length of 1.5m by adopting a three-wheel offset reverse spinning method, and the offset in the three-wheel offset reverse spinning method is set to be 6 mm;
obtaining a first spinning and pressing piece (spinning and pressing piece A), wherein the first spinning and pressing piece (spinning and pressing piece A) is a straight cylinder with equal thickness or a straight cylinder section with two ends provided with outer annular end frames; the dimensions of the first rotary pressing member (rotary pressing member a) are: the total length is 4700mm, the thickness of straight section of thick bamboo is 6mm, both ends end frame section thickness 11 mm.
Step S202, fixed-length processing of the aluminum alloy liner spinning pipe: performing fixed-length processing on the first spinning member (spinning member A) obtained in the step S201 by using a double-column automatic sawing machine to obtain an aluminum alloy liner spinning tube, wherein the length of a straight tube section of the aluminum alloy liner spinning tube is 4600 mm;
step S203, cleaning the aluminum alloy inner container spinning pipe: adding a neutral cleaning agent at 40 ℃ into a rotary spray cleaning machine or an ultrasonic cleaning machine to clean the aluminum alloy liner rotary pressure pipe obtained in the step S202; and after cleaning, removing residual water stains on the surface by using an automatic wiping machine or a drying device.
S204, adopting automatic laser visual detection equipment for the spinning tube, fixing the spinning tube of the aluminum alloy liner obtained in the step S203 on a lathe bed through an automatic clamping device, and carrying out quality detection on the spinning tube;
in the embodiment of the present application, the flow of step S204 is specifically as follows:
s214, programming and rotating the aluminum alloy liner spinning tube, and driving a laser detection mechanism to automatically detect whether the dimensions such as the diameter, the roundness, the straightness, the end face verticality and the like of the aluminum alloy liner spinning tube and the form and position tolerance meet the design requirements;
s224, programming to rotate the aluminum alloy liner spinning tube, and driving the inner surface visual recognition device to automatically detect whether the inner surface has surface defects such as scratches, peeling, folds, surface cracks and the like with the depth of more than 0.1 mm;
and S234, programming to rotate the aluminum alloy liner spinning pipe, driving the outer surface visual identification device, and automatically detecting whether the inner surface has surface defects such as scratches, peeling, wrinkles, surface cracks and the like with the depth of more than 0.1 mm.
Step S205, grinding the aluminum alloy inner container spinning tube: fixing the aluminum alloy liner spinning tube with the surface defects detected in the step S204 on a numerical control inner and outer circle grinding machine through an automatic clamping device, and grinding the inner and outer surfaces of the cleaned aluminum alloy liner spinning tube detected in the step S204 by scratching and bruising;
in the embodiment of the present application, the flow of step S205 is specifically as follows:
step S215, driving the aluminum alloy liner spinning tube to rotate, firstly driving a visual detection device of the inner circle grinding mechanism to position the inner surface defect detected in the step S204, and grinding point by point according to the positioned position, wherein the aluminum alloy liner spinning tube swings in an angle range of-10 degrees to +10 degrees at the speed of 30r/min during grinding;
and step S225, driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the outer surface defect detected in the step S204, and carrying out continuous grinding according to the positioned position.
And S206, carrying out full-automatic flaw detection on the aluminum alloy liner spinning tube obtained in the step S204 by using an ultrasonic automatic flaw detector, and detecting whether the barrel has machining defects such as orange peel and folding.
Step S3, closing the end socket and spinning and forming the bottle mouth: respectively carrying out spin forming on the end socket and the bottle mouth at the openings at the two ends of the aluminum alloy liner spin-pressing pipe by using a heating closing-up spinning machine to obtain a second spin-pressing part (spin-formed part B);
specifically, step S3 includes:
step S301, clamping: clamping the aluminum alloy inner container spinning pipe by adopting a split type hollow main shaft;
step S302, heating: carrying out flame spraying and heating on a spinning part to be closed of the spinning pipe of the aluminum alloy liner to 310 ℃ by adopting oxygen and propane/LNG natural gas combustion;
step S303, forming and spinning of the end socket and the bottle mouth: performing closing-up spinning on the aluminum alloy liner spinning tube heated in the step S302 by adopting a unilateral X-line, Z-line and rotary three-way interpolation type closing-up spinning machine;
in the spinning process, the closing spinning band has 4 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared second spinning part (spinning forming part B) is uniformly and gradually thickened from 6mm of the edge to 25mm of the bottle opening part.
And S304, repeating the operations of the steps S301, S302 and S303 on the other end of the spinning pipe of the aluminum alloy liner to obtain a second spinning piece (spinning formed piece B).
Step S4, processing of a central hole and an excircle of a bottle mouth: clamping a second spinning part (spinning formed part B) by adopting a split type hollow clamping tool, machining a center hole of a bottle opening of the second spinning part (spinning formed part B) obtained in the step S4 by adopting a special bottle opening machining center, and machining an outer circle of an installation column of the back cover to obtain a third spinning part (spinning formed part C); preparing for subsequent heat treatment;
step S5, curved surface flaw detection: performing closing quality flaw detection on the third spinning part (spinning formed part C) obtained in the step S5, and checking whether machining defects such as orange peel and folding exist at the end socket position;
step S6, grinding the inner surface of the curved surface: grinding the defects of the inner surface of the end socket found in the step S5 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third spinning part (spinning formed part C) with qualified quality;
specifically, step S6 includes:
step S601, clamping a third spinning part (spinning formed part C) by adopting a split type hollow clamping tool;
step S602, automatically observing and judging the defect condition of the inner surface of the end socket by adopting a visual recognition system of a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
and S603, grinding the defects of the inner surface of the end socket found in the step S6 by using a numerical control automatic grinding mechanism of a special end socket inner surface grinding machine tool to obtain a third spinning part (spinning formed part C) with qualified quality, wherein the numerical control automatic grinding mechanism can be programmed and independently executed in the grinding process.
Step S7, heat treatment: performing T6 process treatment on the third spinning part (spinning formed part C) obtained in the step S6 to obtain an aluminum alloy inner container blank for the high-pressure gas cylinder;
specifically, step S7 includes:
step S701, quenching: putting the third spinning part (spinning formed part C) prepared in the step S6 into a vertical aluminum alloy box type quenching furnace for quenching treatment, heating the third spinning part (spinning formed part C) to 525-;
step S702, aging treatment: transferring the quenched third spinning part (spinning formed part C) to a trolley type aluminum alloy aging furnace for aging treatment, and finally preserving heat for 9 hours in an environment of 160 ℃ to prepare an aluminum alloy inner container blank for the high-pressure gas cylinder. In the whole quenching treatment and aging treatment processes, the aluminum alloy inner container blank for the high-pressure gas cylinder is vertically fixed in a special heat treatment material frame by adopting a special heat treatment tool.
Step S8, processing bottle mouth: respectively machining the inner diameter and the outer diameter of the opening of the aluminum alloy liner blank for the high-pressure gas cylinder obtained in the step S7 by using a special opening machining center, and machining the inner threads of the opening to obtain an aluminum alloy liner 100 for the high-pressure gas cylinder;
specifically, step S8 includes:
step S801, clamping an aluminum alloy inner container blank for a high-pressure gas cylinder by adopting a split type hollow clamping tool;
step S802, processing a bottle mouth: and (4) carrying out high-speed processing on the outside diameter and the inside diameter of the bottle mouth and the inside thread of the bottle mouth of the aluminum alloy liner blank for the high-pressure gas bottle obtained in the step (S7) by using a special bottle mouth processing center to obtain the aluminum alloy liner 100 for the high-pressure gas bottle, wherein the length, the outside diameter and the inside diameter of the bottle mouth are respectively 40mm, 50mm and 28 mm.
Step S9, inner container cleaning: performing high-pressure water spraying cleaning on the inner cavity of the aluminum alloy liner for the oversized high-pressure gas cylinder obtained in the step S8 by using a special horizontal gas cylinder liner cleaning machine to remove aluminum scraps and other processing pollutants, and drying;
specifically, step S9 includes:
step 901, vertically placing the aluminum alloy inner container 100 for the high-pressure gas cylinder on a special vertical gas cylinder inner container cleaning machine, enabling a spraying mechanism of the special vertical gas cylinder inner container cleaning machine to enter the inner container, and fixing the inner container;
step S902, cleaning the inner cavity of the aluminum alloy inner container 100 for the high-pressure gas cylinder by adopting high-pressure water spraying to remove aluminum scraps and other processing pollutants;
step S903, after the cleaning is finished, starting the turnover frame to incline to 45 degrees, enabling the end sealing end to face downwards, and pouring water;
and step S904, drying the liner by adopting an inward extending type steam dryer.
Step S10, checking the semi-finished product: the aluminum alloy inner container 100 for the high-pressure gas cylinder obtained in step S9 is inspected, and a part of items are subjected to spot inspection at a spot inspection rate of 1 piece per batch (usually, the number of pieces per batch is not more than 200 pieces). The texture grain sizes of any six positions of the aluminum alloy inner container 100 for the high-pressure gas cylinder to be inspected are measured, and the texture grain sizes of the six positions are respectively 6-grade, 7-grade, 6-grade and 5-grade according to the ASTM E112 standard, and the tensile strength of the straight cylinder section of the aluminum alloy inner container 100 for the high-pressure gas cylinder to be inspected is measured. And respectively measuring the yield strength and the elongation, wherein the tensile strength of the straight cylinder section is 345MPa, the yield strength is 310MPa, and the elongation is 16%, and the products produced in the batch are qualified, so that the finished product of the aluminum alloy liner 100 for the high-pressure gas cylinder is obtained.
Step S11, preprocessing the inner container: horizontally placing the aluminum alloy inner container 100 on a coating station of special automatic coating and drying equipment, and coating the aluminum alloy inner container with an anti-galvanic corrosion layer;
specifically, step S11 includes:
step S1101, preparing a glue solution according to a weight ratio of resin to curing agent of 1: 0.85;
step S1102, recording the serial number of the liner, measuring the weight of the liner by using an electronic balance, sleeving tetrafluoro gaskets on the thread positions of a winding tool by using the winding tool with the same threads, screwing the tetrafluoro gaskets to bottle mouths at two ends of the liner by hands, and fixing the liner on a coating device;
step S1103, automatically coating glue solution by adopting an automatic coating rolling brush until the glue solution is uniformly coated on the inner container;
step S1104, adopting a rotary curing mode, according to a curing temperature: 160 ℃, curing time: and curing the inner container within 2 h.
Step S12, carbon fiber winding: adopting a numerical control automatic winding machine to perform carbon fiber winding processing on the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer in the step S11
Specifically, step S12 includes:
step S1201, mounting a bottle mouth outer sleeve at the bottle mouth, and checking the smooth degree of the transition between the bottle mouth outer sleeve and the end socket curved surface section; leading out carbon fiber yarns from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarns on the winding nozzle to finish threading;
step S1202, according to epoxy resin: curing agent 1:0.85 (weight ratio) of mixed epoxy resin and curing agent, pouring the prepared glue solution into a glue dipping tank, wherein the glue content is 25%, opening a heating button of the glue dipping tank, and setting the temperature to a specified temperature;
step S1203, installing two end winding fixing tools on the coated aluminum alloy inner container 100 and fixing the two end winding fixing tools on a winding machine;
step S1204, selecting a winding program, unwinding the yarn tied at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the air bottle until the yarn soaked with resin is pulled on the inner container, setting the tension to be 5N, starting and finishing carbon fiber winding, wherein the thickness of a single layer of winding is 0.464mm, the annular winding angle is +/-89 degrees, and the longitudinal winding angle is +/-15 degrees.
Step S13, winding glass fiber: carrying out glass fiber winding processing on the semi-finished product of the gas cylinder with the layers of carbon fibers wound in the step S11 by adopting a numerical control automatic winding machine;
specifically, step S13 includes:
step S1301, mounting two end winding fixing tools on the semi-finished product of the gas cylinder wound with the carbon fibers obtained in the step S12 and fixing the semi-finished product on a winding machine;
step S1302, pasting two labels with the same number on two sides of the middle part of the gas cylinder;
step S1303, leading out the glass fiber yarn from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarn on the winding nozzle to finish yarn threading;
step S1304, pressing epoxy resin: curing agent 1:0.85 (weight ratio) of mixed epoxy resin and curing agent, pouring the prepared glue solution into a glue dipping tank, wherein the glue content is 40 percent, opening a heating button of the glue dipping tank, and setting the temperature to a specified temperature;
step S1305, selecting a winding program, unwinding the yarn at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the air bottle until the yarn soaked with resin is pulled on the inner container, setting the tension to be 5N, finishing the winding of 1 layer of circular glass fiber, wherein the thickness of a single layer of the winding is 0.464mm, and the circular winding angle is +/-89 degrees.
Step S14, curing: a box-type heating furnace with the function of supporting the gas cylinder to automatically rotate in the furnace is adopted for curing the gas cylinder, and a stepped temperature rise and fall curve is adopted for curing;
specifically, step S14 includes:
step S1401, a special lifting device capable of lifting winding tools at two ends is adopted to place a winding gas cylinder on a box type heating furnace support frame, and a rotary joint of the box type heating furnace is fixed with the winding tools through a positioning pin;
step S1402, the equipment is transferred into a program model, preheating and heating are set to 80 ℃, heat preservation is carried out for 1 hour, then heating is carried out to 120 ℃, heat preservation is carried out for 2 hours, and a starting key is opened for curing after a programmed curing program is selected;
and step S1303, when the heat is preserved, automatically opening the box type heating furnace to cool down to 40 ℃, opening the equipment door, and moving the solidified gas cylinder to the next procedure.
Step S15, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests of the gas cylinder one by one;
specifically, step S15 includes:
and step S1501, connecting the tested bottle with a hydrostatic testing machine through a hydrostatic joint after the tested bottle is filled with water. No gas should be present in the pipeline;
step S1502, carrying out self-tightening water pressure on a tested bottle, wherein the self-tightening pressure is 1.8 times of the use pressure, namely 45Mpa, the boosting rate does not exceed 0.5MPa/S in the boosting process, keeping the pressure for 5min under the self-tightening pressure after the bottle is pressurized, and then releasing the pressure, wherein the test temperature is room temperature, and the test medium is water;
step S1503, carrying out a hydrostatic test on the tested bottle, wherein the pressure is 1.5 times of the use pressure, namely 37.5Mpa, the pressure increasing rate is not more than 0.5MPa/S in the pressure increasing process, the pressure is maintained for 30S after the pressure is reached, then the pressure is released, the test temperature is room temperature, the test medium is water, and the volume residual deformation rate is not more than 5%.
Step S16, airtight test: carrying out air tightness leakage detection tests on the air cylinders one by adopting an integrated air tightness testing machine with an explosion-proof function;
specifically, step S16 includes:
step S1601, placing a tested bottle in an airtight test box, immersing the tested bottle in water, and connecting a test pipeline;
and step S1602, performing a water immersion method airtight test, keeping the test pressure of 0-25 MPa and the test temperature at room temperature for 1min by using test medium compressed air, and observing by using a high-definition camera, wherein no bubbles are generated in the pressure keeping process.
Step S17, fatigue test: performing sampling inspection verification on the fatigue performance of the gas cylinder by adopting a fatigue pressure cycle tester according to the proportion of one gas cylinder in each batch;
the test pressure is 0MPa to 27MPa, the test temperature is room temperature, and the test medium oil or water is subjected to pressure cycle for at least 15000 times from 0MPa to 27 MPa; the bottle should not leak or burst.
Step S18, blasting test: and (4) performing sampling inspection verification on the blasting performance of the gas cylinders by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch. During the test, the gas cylinder is pressurized to 56.25MPa by adopting an aqueous medium, and after the pressure is maintained for 5s, the gas cylinder is not damaged and is qualified. Pressurization thereafter continues until failure.
It can be seen from the above embodiments that the high-pressure gas cylinder manufactured by the method for manufacturing the high-pressure fully-wound gas cylinder with the aluminum alloy liner 100 provided by the embodiment of the application has a nominal outer diameter of phi 406-phi 850mm, and the volume of the high-pressure gas cylinder is far higher than that of the existing standard aluminum alloy liner 100; the wall thickness of the straight cylinder section is 1-10mm, and the straight cylinder section has the characteristics of thin wall thickness and light weight; the tensile strength of the straight cylinder section is more than or equal to 345MPa, the yield strength is more than or equal to 310MPa, and the elongation is more than or equal to 15 percent; the grain size of the tissue at any position of the straight cylinder section is more than or equal to 5 grades according to the standard of ASTME112, the tissue of the material in the straight cylinder section is uniform and compact, the whole strength effect is excellent, the straight cylinder section has the characteristic of high pressure resistance, the energy consumption is low, the pollution is small, the loss of raw materials in the whole manufacturing process is less, and the raw material cost is saved.
The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims (10)
1. The utility model provides an aluminum alloy inner bag high pressure full winding gas cylinder of one end back cover which characterized in that includes: the aluminum alloy liner, the composite material reinforcing layer and the external protective layer;
the aluminum alloy inner bag is the seamless structure of integral type of one end back cover, other end binding off shaping head and bottleneck, includes: the bottle comprises a bottle mouth, a sealing head, a straight cylinder section, a back cover and a back cover, wherein the sealing head and the back cover are respectively positioned at two ends of the straight cylinder section, and the bottle mouth is positioned on the sealing head; the length of the aluminum alloy inner container is less than 5 meters, the nominal outer diameter of the straight cylinder section is phi 406-phi 850mm, and the rated pressure of the high-pressure gas cylinder is 20-30 Mpa; the method comprises the following steps of preparing a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end by adopting reverse extrusion forming, carrying out multi-pass strong external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control strong external spinning press to obtain an aluminum alloy inner container spinning pipe, and carrying out scratch and collision grinding on the inner and outer surfaces of the aluminum alloy inner container spinning pipe with surface defects detected by adopting a numerical control inner and outer circle grinding machine after the fixed-length processing, cleaning and defect inspection of the aluminum alloy inner container spinning pipe; when the aluminum alloy inner container spinning tube is ground, the aluminum alloy inner container spinning tube is driven to rotate, the inner circle grinding mechanism is driven to carry out positioning on the detected inner surface defects through visual detection equipment, and point-by-point grinding is carried out according to the positioned positions; during grinding, the aluminum alloy liner spinning pipe swings at the speed of 30r/min within the angle range of (-10 degrees and 10 degrees); driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the detected outer surface defects, and continuously grinding according to the positioned position;
the composite material reinforcing layer is coated on the outer side of the aluminum alloy inner container, wherein the composite material reinforcing layer is formed by winding carbon fibers in a spiral and annular combined winding mode and curing the carbon fibers with resin;
the outer protective layer is coated on the outer side of the composite material reinforcing layer, wherein the outer protective layer is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin.
2. The aluminum alloy liner high-pressure fully-wound gas cylinder with one end sealed according to claim 1, characterized in that the length of the gas cylinder is not more than 5m, the nominal outer diameter is (406, 850) mm, and the working pressure is (20, 30) MPa; the volume of the gas cylinder is (280, 2800) L;
preferably, the length of the gas cylinder is (2.8, 5) m;
preferably, the working pressure of the gas cylinder is 20 MPa;
preferably, the cylinder has a volume of (280, 510) L;
preferably, the service temperature of the gas cylinder is (-40 ℃, 85 ℃);
preferably, the gas cylinder is used for containing CNG gas and high-purity industrial gas;
preferably, the gas cylinder is used for a fuel gas cylinder placed horizontally on a vehicle and a vehicle-mounted storage and transportation gas cylinder prevented from being placed vertically;
preferably, the wall thickness of a straight cylinder section of the aluminum alloy inner container is (1, 10) mm, and the integral straightness of the straight cylinder section is not more than 0.5 mm/m;
preferably, the tolerance of the wall thickness of the straight cylinder section is less than or equal to +/-0.15 mm;
preferably, the local straightness at any straight section position of the straight cylinder section is not more than 0.5mm/300 mm;
preferably, the roundness of any position of the straight cylinder section is not more than 0.5 mm;
preferably, the roughness of the inner surface of the straight cylinder section is less than Ra1.6 μm, and the roughness of the outer surface of the straight cylinder section is less than Ra3.2 μm.
3. The aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed according to claim 1, wherein the thickness of the seal head is uniformly thickened gradually from the edge to the opening part;
preferably, the thickness of the seal head is uniformly and gradually thickened from (5,8) mm of the edge to (10,25) mm of the bottle mouth part;
preferably, the thickness of the back cover is uniformly and gradually increased from (5,8) mm at the edge to (10,25) mm at the bottom of the back cover;
preferably, the end socket can adopt an ellipsoidal end socket, a butterfly end socket or a hemispherical end socket, and the structural type of the end socket is the same as the curved surface structural type of the end socket; the thickness of the back cover is uniformly and gradually thickened from the edge to the center of the back cover;
preferably, the length of the bottle mouth is 40mm, the outer diameter of the bottle mouth is 50mm, and the inner diameter of the bottle mouth is 28 mm.
4. The aluminum alloy liner high-pressure fully-wound gas cylinder with one end sealed according to claim 1, characterized in that the carbon fibers of the composite material reinforcing layer and the glass fibers of the outer protective layer are wound by a wet method;
preferably, the carbon fibers are continuous untwisted carbon fibers;
preferably, the tensile strength of the carbon fiber is not less than 4300 MPa; the winding tension of the carbon fiber winding is not less than 5N;
preferably, the resin is a thermosetting resin, and the glass transition temperature of the resin is not lower than 105 ℃;
preferably, the resin is epoxy resin or modified epoxy resin;
preferably, the carbon fibers and/or the glass fibers are cured by a box-type heating furnace within 4 hours after being wound, and the gas cylinder is rotated automatically all the time during curing.
5. The aluminum alloy inner container high-pressure fully-wound gas cylinder with one end sealed according to claim 1, characterized in that the gas cylinder needs to be subjected to self-tightening water pressure, water pressure and air tightness tests, fatigue and explosion tests;
preferably, the water pressure of the self-tightening water is 1.8 times of the using pressure of the gas cylinder;
preferably, the fatigue times of the gas cylinder fatigue test are not less than 15000 times.
6. A method for manufacturing a high-pressure fully-wound gas cylinder with an aluminum alloy inner container with one end sealed is used for manufacturing the high-pressure fully-wound gas cylinder with the aluminum alloy inner container with one end sealed according to any one of claims 1 to 5, and is characterized by comprising the following steps of:
step S1, carrying out integral reverse extrusion forming on the blank with the back cover;
the step S1: adopting a heating backward extrusion process combined with turning and boring processes to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end; the method specifically comprises the following steps:
heating an aluminum ingot, and preheating the aluminum ingot to be extruded to 200-400 ℃;
heating the mold, and preheating the outer extrusion mold and the inner extrusion rod to 200-400 ℃;
extrusion molding, namely placing an aluminum ingot in an extrusion die, and extruding the blank for multiple times into a prefabricated pipe blank with a bottom seal under the condition of continuous heating and temperature preservation;
processing the outer surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a turning method;
processing the inner surface of the prefabricated pipe blank to the size required by the spinning blank by adopting a boring method to prepare a seamless pipe consisting of a back cover and a straight cylinder section with an opening at one end;
step S2, preparing an aluminum alloy inner container spinning pipe: carrying out multi-pass powerful external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control powerful external spinning machine to obtain an aluminum alloy inner container spinning pipe; wherein, step S2 specifically includes:
step S201, spinning and forming a straight cylinder section of the aluminum alloy liner spinning pipe: carrying out 2-4 times of spinning process on the seamless pipe by adopting a three-wheel staggered forward spinning or backward spinning method to obtain a first spinning piece; when in forward spinning, a core mould with the processing length equal to 1.2-1.4 times of the length of a set product is adopted for spinning auxiliary processing; during reverse spinning, a core mold with the processing length equal to 0.6-0.8 time of the length of a set product is adopted for spinning auxiliary processing;
step S202, fixed-length processing of the aluminum alloy liner spinning pipe: performing fixed-length processing on the first spinning piece obtained in the step S201 to obtain an aluminum alloy liner spinning pipe;
step S203, cleaning the aluminum alloy inner container spinning pipe: cleaning the aluminum alloy inner container spinning pipe obtained in the step 202 by using a cleaning machine;
step S204, checking the aluminum alloy inner container spinning pipe: inspecting the shape and size tolerance of the aluminum alloy liner spinning tube by adopting size, shape tolerance and surface defect detection equipment, and automatically detecting whether the inner surface and the outer surface have defects;
step S205, grinding the aluminum alloy inner container spinning tube: and (3) carrying out grinding of scratches and damages of the inner surface and the outer surface of the aluminum alloy liner spinning tube with the surface defects detected in the step (S204) by adopting a numerical control inner and outer circle grinding machine, wherein the grinding process comprises the following steps:
s215, driving the aluminum alloy liner spinning pipe to rotate, driving a visual detection device of the inner circle grinding mechanism to position the inner surface defects detected in the step S204, and grinding point by point according to the positioned position; during grinding, the aluminum alloy liner spinning pipe swings at the speed of 30r/min within the angle range of (-10 degrees and 10 degrees);
s225, driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the outer surface defect detected in the step S104, and continuously grinding according to the positioned position;
step S206, carrying out full-automatic flaw detection on the straight cylinder section of the aluminum alloy liner spinning pipe obtained in the step S205 by using a special ultrasonic automatic flaw detector, and detecting whether a processing defect exists;
step S3, closing the end socket and spinning and forming the bottle mouth: spinning and forming the end socket and the bottle mouth at the opening of the aluminum alloy liner spinning tube by adopting a heating closing-up spinning machine to obtain a second spinning piece;
step S4, processing a central hole of the bottle mouth: machining a central hole of the bottle opening of the second spinning piece obtained in the step S3 to obtain a third spinning piece;
step S5, curved surface flaw detection: performing closing quality flaw detection on the third spinning part obtained in the step S4, and checking whether a machining defect exists at the end socket position;
step S6, grinding the inner surface of the curved surface: grinding the inner surface defects of the end socket found in the step S5 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third rotary pressing piece with qualified quality;
step S7, heat treatment: carrying out T6 process treatment on the third spinning piece obtained in the step S6 to obtain an aluminum alloy inner container blank;
step S8, processing bottle mouth: respectively machining the inner diameter and the outer diameter of the bottle mouth of the aluminum alloy liner blank obtained in the step S7 by using a special bottle mouth machining center, and machining threads in the bottle mouth to obtain an aluminum alloy liner;
step S9, cleaning the inner container;
step S10, checking the semi-finished product: performing spot inspection on the aluminum alloy inner container obtained in the step S9;
step S11, preprocessing the inner container: horizontally placing the aluminum alloy liner in the step S10 on a coating station of special automatic coating and drying equipment by adopting the special automatic coating and drying equipment, and coating the aluminum alloy liner with an anti-galvanic corrosion layer;
step S12, carbon fiber winding: adopting a numerical control automatic winding machine to perform carbon fiber winding processing on the aluminum alloy inner container coated with the anti-galvanic corrosion layer in the step S11 in a winding mode of combining spiral and annular directions to form a composite material reinforcing layer of the gas cylinder;
step S13, winding glass fiber: carrying out glass fiber winding processing on the gas cylinder semi-finished product of the multi-layer carbon fiber wound in the step S12 in a spiral and annular combined winding mode by using a numerical control automatic winding machine to form an external protective layer of the gas cylinder;
step S14, curing: based on a stepped temperature rise and drop curve, a box-type heating furnace with a function of supporting the gas cylinder to automatically rotate in the furnace is adopted to solidify the gas cylinder;
step S15, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests on the gas cylinder one by one;
step S16, airtight test: carrying out air tightness leakage detection tests on the air cylinders one by adopting an integrated air tightness testing machine with an explosion-proof function;
step S17, fatigue test: performing sampling inspection verification on the fatigue performance of the gas cylinder by adopting a fatigue pressure cycle tester according to the proportion of one gas cylinder in each batch;
step S18, blasting test: and (4) performing selective inspection verification on the blasting performance of the gas cylinder by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch.
7. The method for manufacturing the high-pressure fully-wound gas cylinder with the aluminum alloy inner container with one end sealed according to claim 6, wherein in step S2:
preferably, the offset amount in the three-wheel offset forward spinning or reverse spinning method in the step S201 is set to be 6-12 mm;
preferably, the equipment used in the three-wheel offset forward spinning or backward spinning method in step S201 is full-automatic spinning equipment with automatic grease spraying, automatic feeding and discharging, and automatic spinning pressure detecting functions;
preferably, the cleaning machine in step S203 is a rotary spray cleaning machine or an ultrasonic cleaning machine;
preferably, the cleaning of the aluminum alloy inner container spinning pipe is completed by a heated (30 ℃, 45 ℃) neutral cleaning agent;
preferably, after the aluminum alloy inner container spinning tube is cleaned, a special wiping tool or a drying device is adopted to remove residual water stains on the surface;
preferably, the surface defect detecting device in step S204 is a spinning tube laser vision automatic detecting device;
preferably, in step S204, the surface defect detecting device automatically detects whether the inner surface and the outer surface of the aluminum alloy liner spinning tube are scratched;
preferably, the numerical control inner and outer circle sharpening machine adopted in the step S205 has a visual rechecking function;
preferentially, in step S206, the special ultrasonic automatic flaw detector performs full-automatic flaw detection on the straight cylinder section of the aluminum alloy liner spinning tube, and detects whether the straight cylinder section of the aluminum alloy liner spinning tube has peeling, wrinkles and cracks.
8. The manufacturing method of the high-pressure full-wound gas cylinder with the aluminum alloy inner container with one end sealed as claimed in claim 6, wherein the step S3 comprises the following steps:
step S301, clamping: clamping the aluminum alloy inner container spinning pipe by adopting a split type hollow main shaft;
step S302, heating: heating the spinning part of the spinning pipe of the aluminum alloy inner container to be contracted to 200-400 ℃;
step S303, forming and spinning of the end socket and the bottle mouth: performing multi-pass necking spinning on the aluminum alloy liner spinning tube heated in the step S202 by adopting a unilateral X straight line, a unilateral Z straight line and a rotary three-way interpolation type necking spinning machine; wherein, in the spinning process, the closing spinning band has 4 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the second spinning piece is uniformly and gradually thickened from (5,8) mm at the edge to (10,25) mm at the bottle opening part;
step S304, processing a center hole of the on-site bottle mouth of the second spinning piece in the step S303;
preferably, the heating in step S202 is performed by using oxygen or propane/LNG natural gas for combustion flame heating;
preferably, the processing of the center hole of the in-place bottle mouth in the step S305 adopts multi-axis automatic processing.
9. The manufacturing method of the high-pressure full-wound gas cylinder with the aluminum alloy inner container with one end sealed as claimed in claim 6, wherein the step S6 comprises the following steps:
s601, clamping a third spinning part by using a special clamping tool;
step S602, automatically observing and judging the defect condition of the inner surface of the end socket by adopting an automatic endoscope system arranged on a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;
step S603, grinding the defects of the inner surface of the end socket found in the step S4 by using an inner surface grinding mechanism of the end socket of a special end socket inner surface grinding machine tool to obtain a third rotary pressing piece with qualified quality;
preferably, the clamping tool of the third spinning part is a split hollow clamping tool;
preferably, the grinding of the inner molded surface of the end socket is a programmable and independently executed numerical control automatic grinding mechanism.
10. The manufacturing method of the high-pressure full-wound gas cylinder with the aluminum alloy inner container with one end sealed as claimed in claim 6, wherein the step S7 comprises the following steps:
step S701, quenching: putting the third spinning part prepared in the step S5 into a quenching furnace for quenching treatment, heating the third spinning part to 525-531 ℃, preserving the heat for 2-4 hours in the environment of 525-531 ℃, and then quenching the third spinning part;
step S702, aging treatment: transferring the quenched third spinning piece to an aging furnace for aging treatment, and finally, preserving the heat for 6-10 hours in an environment of 160-200 ℃ to prepare an aluminum alloy inner container blank;
preferably, the quenching and aging are carried out by heat treatment in a horizontal continuous quenching and aging furnace.
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