CN114367727A - 丝焊接及研磨站 - Google Patents

丝焊接及研磨站 Download PDF

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CN114367727A
CN114367727A CN202210136221.6A CN202210136221A CN114367727A CN 114367727 A CN114367727 A CN 114367727A CN 202210136221 A CN202210136221 A CN 202210136221A CN 114367727 A CN114367727 A CN 114367727A
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welding
grinding
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K·肖
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Bekaert NV SA
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02Carriages for supporting the welding or cutting element
    • B23K37/0294Transport carriages or vehicles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • B23K11/002Resistance welding; Severing by resistance heating specially adapted for particular articles or work
    • B23K11/0026Welding of thin articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F15/00Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire
    • B21F15/02Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire
    • B21F15/06Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material
    • B21F15/08Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material making use of soldering or welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • B23K11/02Pressure butt welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • B23K11/24Electric supply or control circuits therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • B23K11/24Electric supply or control circuits therefor
    • B23K11/241Electric supplies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • B23K11/28Portable welding equipment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K28/00Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
    • B23K28/02Combined welding or cutting procedures or apparatus
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/006Safety devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/08Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for flash removal
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0047Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with monitoring or indicating devices or circuits
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02PCONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P1/00Arrangements for starting electric motors or dynamo-electric converters
    • H02P1/16Arrangements for starting electric motors or dynamo-electric converters for starting dynamo-electric motors or dynamo-electric converters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00Articles made by soldering, welding or cutting
    • B23K2101/32Wires
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02PCONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P27/00Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
    • H02P27/04Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage
    • H02P27/06Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Power Engineering (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Grinding Of Cylindrical And Plane Surfaces (AREA)
  • Arc Welding Control (AREA)

Abstract

一种丝焊接及研磨站(100),包括焊丝机(112),AC电动机(114),用于向金属研磨机(116)供电,以及AC电源(110),用于为焊丝机(112)和AC电动机(114)两者供电。站(100)还包括软启动模块(118),以减少在启动时AC电动机(114)所需的涌入电流。软启动模块(118)的使用允许使用电池(102)作为电源,并且使用电池作为电源的优点在于实用的可移动性和稳定的焊接电流。

Description

丝焊接及研磨站
本申请是于2018年7月4日向国际局提出、优先权日为2017年8月29日、于2020年2月28日进入中国国家阶段、国家申请号为201880056349.3、发明名称为“丝焊接及研磨站”的中国发明专利申请的分案申请。
技术领域
本发明涉及一种丝焊接及研磨站。
背景技术
丝通常可以以离散长度获得或供应。经常需要将两段丝结合起来以达到所需长度或实现过程的连续性。
通常通过焊接及随后的研磨操作来完成两段金属丝(如钢丝)的结合。
在每段丝的端部形成扁平垂直面。将丝的端部对准压在一起以进行镦锻,并随后电加热至焊接温度,使得端部焊接在一起。然后,保持压力直到焊接材料固化。由于所施加的压力,直径可能在焊接点处增大。之后进行研磨以将直径减小到原始值。
由于丝的低热惯性会导致迅速加热和冷却,焊接期间的微小参数变化会导致金属结构和焊接质量的大变化。因此,商业电网输送的电力供应波动会引起焊接中的质量变化。
另一个问题是,从焊接站到商业电网的连接需要长电线。焊接站必须是可移动的,以允许将焊机带至其它焊接地点。这需要在工厂基础设施中安装多个GFCI(接地故障电路断流器)电源插座以就近使用,并且需要电源线足够长以允许焊接站在工作区域的范围内使用。由于电线的可移动性,电线无法充分固定并避免因加工设备造成的损坏或缠结而变成跳闸隐患或电隐患,因此,电线的使用对雇员造成了安全隐患。
另外,通过由AC电动机供电的研磨机进行修整。由于AC电动机需要高启动电流,即,所谓的涌入电流,该AC电动机还需要直接连接至电网,这增加了其它长电线并且增加了上述问题的复杂性。
发明内容
本发明的主要目的在于解决现有技术的问题。
本发明更具体的目的在于避免或减少对到焊接站和研磨站的长电线的需求。
本发明的另一个目的在于提供一种实用且可自由移动的焊接及研磨站。
根据本发明,提供了一种单一及组合的丝焊接及研磨站。该站包括焊丝机、用于向金属研磨机供电的AC电动机以及AC电源,AC电源用于为焊丝机和AC电动机两者供电。该站还包括软启动模块,软启动模块能够将研磨机AC电动机的启动时间缩短2秒,以减少在启动时AC电动机所需的涌入电流。在没有这种软启动模块的情况下,AC电动机的启动伴随有涌入电流,用如电流高达运行电流的七到十倍。启动扭矩可以高达运行扭矩的三倍。这种增加的电流使得电源承受压力。软启动模块临时降低了传动系的负载和扭矩以及电动机启动期间的电涌。
术语“丝焊接及研磨站”是指用于丝和金属帘线或金属绳(例如钢丝、钢帘线和钢丝绳)两者的焊接及研磨站。
软启动模块有利于将焊丝机和研磨机组合在一个具有一个单一电源的单一站中。
更特别且优选地,AC电源是由电池供电的逆变器。软启动模块防止逆变器由于过载而发生故障。此外,软启动模块使得电池能够通过逆变器为焊丝机和AC电动机两者供电。电池的存在消除了对长电线连接的需求。换句话说,软启动模块的使用允许使用电池作为电源,并且使用电池作为电源的优点在于实用的可移动性和稳定的焊接电流,因为其与供电网络的波动无关。
优选地,接地故障电路断流器被安装在逆变器与焊丝机/AC电动机之间。
根据本发明,组合的丝焊接及接地站优选包括电池充电指示器,以向操作者显示电池何时必须要再充电。
在本发明的优选实施例中,组合的丝焊接及接地站是这样一个单元,其可以由一个单独的操作者容易地从一个工作区域移动到另一工作区域,而无需缠绕和展开电线,并且不需要断开和再次连接至商业电网。
在本发明的另一实际实施例中,丝焊接及研磨站还包括便携式推车。这种便携式推车被设计为保持备用或备份电池和电池充电器。该推车用于安全且有效地将备用电池从焊接站移动至电力补充点,并且反之亦然。仅需要最小长度的电线。
附图说明
图1示出根据本发明的组合的焊接及研磨站的总体方案。
图2示意性地示出作为组合的焊接及研磨站的辅助装置的便携式推车。
具体实施方式
从图1开始,根据本发明的组合的焊接及研磨站100具有深循环12伏电池102,其将DC电流104供应至120伏功率逆变器106。该逆变器106必须足够大以提供获得钢丝的期望焊接所需的15安培的AC。接地故障电路断流器108被定位在逆变器106和站100的其余部分之间的AC连接上。逆变器将AC电流110提供给焊丝机112和AC电动机114,AC电动机114驱动研磨机116。AC电动机114具有120伏软启动模块118,以减少AC电动机114在启动期间所需的涌入电流。由该软启动模块118导致的小延迟对可用性没有显著影响。软启动模块的一个示例是Schneider Electric ATS01N112FT型软启动模块。焊丝机112还配备有两个保持模具120、122,每个保持模具保持待焊接在一起的丝端部124、126。保持模具120、122允许对准丝端部124、126,以将其压在一起并向其馈送电流来执行焊接。此外,焊接及研磨站100
转到图2,组合的焊接及研磨站100还可以具有作为辅助设备的便携式推车202,该推车具有备用电池204和120伏电池充电器。备用电池204由120伏充电器使用标准基础设施电连接的最小长度电线208充电。推车可以安全且有效地移入和移出焊接及研磨站100。这具有附加的优点,即,焊接及研磨站100在功率补充期间保持在使用点处。
每个焊接及研磨站100能够在每次电池充电后产生超过40次焊接,其中精确的数量取决于钢丝直径。实践表明,焊接及研磨站100可以使用至少十二个小时。
根据本发明的焊接及研磨站特别适用于低碳钢丝和高碳钢丝、钢帘线、钢丝绳的焊接和研磨。
低碳钢丝的丝直径可以在0.4mm至10.0mm的范围内。
高碳钢丝的丝直径可以在0.10mm至15.0mm及以上的范围内。
钢帘线包括绞捻在一起的多根单钢丝。单钢丝的直径范围为0.15mm至0.60mm,例如对于轮胎帘线用途,单钢丝的直径范围为0.15mm至0.40mm。
这里使用的术语“直径”不一定意味着丝或单丝均具有圆形横截面。非圆形丝或单丝的直径是具有与非圆形丝或单丝相同横截面的圆的直径。
在钢帘线的情况下,所有单丝或仅其一部分将被焊接在一起。
低碳钢丝的碳含量通常在0.04wt%至0.20wt%之间的范围内。低碳钢丝的完整组分可以按照以下方式:碳含量为0.06wt%,硅含量为0.166wt%,铬含量为0.042wt%,铜含量为0.173wt%,锰含量为0.382wt%,钼含量为0.013wt%,氮含量为0.006wt%,镍含量为0.077wt%,磷含量为0.007wt%,硫含量为0.013wt%,其余为铁和不可避免的杂质。
高碳钢丝的碳含量的范围通常在从0.40wt%至1.20wt%,例如0.70wt%至1.1wt%的范围内;锰含量为从0.10wt%至1.0wt%,例如从0.20wt%至0.80wt%;硅含量为从0.10wt%至1.50wt%,例如从0.15wt%至0.70wt%;硫含量低于0.03wt%,例如低于0.01wt%;磷含量低于0.03wt%,例如低于0.01wt%,余量为铁和可能的微合金化元素,如铬、钒、钼、铜、铌,其总量最多至0.4wt%。
附图标记列表
100 组合的焊接及研磨站
102 电池
104 DC电流
106 逆变器
108 GFCI
110 AC电流
112 焊丝机
114 AC电动机
116 研磨机
118 软启动模块
120 保持模具
122 保持模具
124 丝端部
126 丝端部
128 电池充电指示器
202 便携式推车
204 备份电池或备用电池
206 伏充电器
208 电线

Claims (12)

1.一种能够自由移动的丝焊接及研磨站,
所述站包括焊丝机,
AC电动机,用于向金属研磨机供电,以及
AC电源,用于为所述焊丝机和所述AC电动机两者供应电力,
所述站还包括软启动模块,以减少在启动时所述AC电动机所需的涌入电流,由此提供稳定的焊接电流。
2.根据权利要求1所述的能够自由移动的丝焊接及研磨站,
所述AC电源为DC/AC换流器,
所述站还包括电池,
所述电池为所述换流器供应电力。
3.根据权利要求1所述的能够自由移动的丝焊接及研磨站,
所述站还包括仅一个接地故障电路断流器,
所述接地故障电路断流器位于在一侧的所述逆变器和在另一侧的焊接电极和AC电动机之间。
4.根据权利要求2或3所述的能够自由移动的丝焊接及研磨站,
所述站还包括电池充电指示器,以向操作者显示所述电池何时应当被再充电。
5.根据权利要求2至4中任意一项所述的能够自由移动的丝焊接及研磨站,
所述站构成能够由一个单独的操作者移动的单元。
6.根据权利要求2至5中任意一项所述的能够自由移动的丝焊接及研磨站,
所述站还包括便携式推车,
所述推车被设计为保持备用电池和电池充电器。
7.根据权利要求1至6中任一项所述的能够自由移动的丝焊接及研磨站,所述丝焊接及研磨站用于焊接和研磨直径范围为从0.4mm至10.0mm的低碳钢丝。
8.根据权利要求1至6中任一项所述的能够自由移动的丝焊接及研磨站,所述丝焊接及研磨站用于焊接和研磨直径范围为从0.10mm直至15.0mm及以上的高碳钢丝。
9.根据权利要求1至6中任一项所述的能够自由移动的丝焊接及研磨站,所述丝焊接及研磨站用于焊接和研磨钢帘线,所述钢帘线包括绞捻在一起的多根钢单丝,并且所述钢单丝的直径范围为从0.15mm直至0.60mm。
10.根据权利要求1所述的能够自由移动的丝焊接及研磨站,所述丝焊接及研磨站独立于供电网络。
11.根据权利要求1所述的能够自由移动的丝焊接及研磨站,其中一个电池充电的容量足以进行至少40次焊接。
12.根据上述权利要求中任一项所述的能够自由移动的丝焊接及研磨站用于焊接和研磨低碳钢丝、高碳钢丝和钢帘线中的一种的用途。
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