KR20120057671A

KR20120057671A - Manufacturing Method of Air Tank

Info

Publication number: KR20120057671A
Application number: KR1020100073113A
Authority: KR
Inventors: 안기환
Original assignee: 흥건정공 주식회사
Priority date: 2010-07-29
Filing date: 2010-07-29
Publication date: 2012-06-07

Abstract

PURPOSE: An air tank manufacturing method is provided to prevent delamination of coating due to spatter by removing spatter from a welded portion and threads of a seat using a chisel and a gimlet. CONSTITUTION: An air tank manufacturing method comprises a drum manufacturing process in which a seat(13) is welded to a hole of a drum-shaped metal plate and a plating solution is applied to the inner surface of the metal plate to complete a drum(10), first and second cover manufacturing processes in which metal plates are molded into a hemispherical shape, a plating solution is applied to the inner surfaces of the hemispherical metal plates, the coated metal plates are joggled, a seat(14) is welded to a hole of the joggled metal plates, and spatter is removed from the welded seat to complete first and second covers(11,12), a cover fixing process in which the first and second covers are press-fitted to the right and left sides of the drum, and an air tank-shaped container forming process in which the edges of the drum are welded along the circumference thereof to obtain an air tank-shaped container.

Description

Manufacturing Method of Air Tank

The present invention relates to a method of manufacturing an air tank, and more particularly, to a method of manufacturing an air tank used in a brake system of a medium-large vehicle including a commercial vehicle.

A full air type brake system provided in a medium and large vehicle generally includes an air compressor driven by power generated from an engine to produce high pressure compressed air, an air tank for storing the compressed air, And a brake chamber having a diaphragm pressurized by the compressed air stored in the air tank.

The air tank is used to provide high pressure compressed air stored in a large vehicle, for example, a bus or a truck, to store the brake function required for braking the vehicle.

In other words, medium and large vehicles for loading heavy loads adopt a pneumatic brake system with excellent braking force in order to stably control the running speed of heavy vehicles while making heavy weight of the vehicle body. Such a pneumatic brake system is usually stored in the air tank through the inlet pipe, the compressed air made by the air compressor interlocked with the engine of the vehicle, the compressed air stored in the air tank is discharged through the outlet pipe by the operation of a separate brake device As a result, a series of continuous operation processes that operate the brake chamber and the wheel cylinders that interlock with the brake chamber are designed to reduce or stop the speed of the vehicle.

As described above, the function and importance of the air tank for introducing and extracting compressed air in a medium and large vehicle using a pneumatic braking device will be greater than that. Therefore, it is necessary to devise a method of manufacturing a preferred air tank.

The present invention has been made to solve the above problems, and an object thereof is to provide a method of manufacturing an air tank that can be adopted for a long time more stably in a medium-large vehicle.

In order to achieve the above object, the present invention, the step of preparing a metal plate for the production of the drum, the step of processing the prepared metal plate into a plurality of holes perforated drum shape, fixed by welding the sheet in the hole of the drum-shaped metal plate And a step of brushing the surface of the metal plate on which the sheet is welded, and applying a coating liquid to the inner surface of the brushed metal plate;

Preparing a metal plate for fabricating the first cover, molding the prepared metal plate into a hemispherical shape with a plurality of holes perforated, applying a coating liquid to the inner surface of the hemispherical metal plate, and joggling the coated hemispherical metal plate. And a step of welding the sheets to the holes of the joggly formed metal plate, and removing the spatters around the welded sheets;

A second step consisting of preparing a metal plate for the manufacture of the second cover, molding the prepared metal plate into a hemispherical shape, applying a coating liquid to the inner surface of the hemispherical metal plate, and joggling the coated hemispherical metal plate. Manufacturing process of cover;

Pressing and fixing the first cover and the second cover manufactured in the first cover and the second cover manufacturing process, respectively, on the left and right sides of the drum manufactured in the drum manufacturing process, and the first cover and the second cover are press-fitted. It provides a method of manufacturing an air tank comprising a step of forming a container of the air tank shape by circumferentially welding the edge of the drum.

Preferably, the step of processing the prepared metal plate in the shape of a drum punched hole, cutting the metal plate to a predetermined size and punching a hole on one side; Rolling the metal plate into a drum shape; Applying a spatter inhibitor to the metal plate wound in a drum shape; Aligning and welding the side steps of the woven welding portion of the metal plate coated with the anti-spatter; It characterized in that the step consisting of welding the welded portion of the welded metal plate in a drum shape.

More preferably, the container is dried and passed through a coating device to apply powder coating, assembling a connector to a sheet of the container coated with powder coating, filling the container with air, and performing a leak test on the container and Checking the airtight state of the connector assembly portion, characterized in that it further comprises the step of removing and cleaning the internal foreign matter of the container passing the leak test.

More preferably, the inner coating of the first cover and the second cover is carried out simultaneously in the step of applying the coating liquid to the inner surface of the brushed metal plate during the drum manufacturing process.

More preferably, further comprising the step of removing foreign substances and oil by washing the hemispherical metal plate coated with the coating liquid.

More preferably, it further comprises the step of removing the spatter formed on the weld surface of the drum and the first cover and the second cover.

More preferably, the method further comprises the step of tapping and correcting the weld deformed thread of the sheet.

More preferably, further comprising the step of attaching a cursion label indicating the thickness of the container coating film on the surface of the container coated with the powder coating.

The method of manufacturing an air tank according to the present invention provides an air tank that can be used more stably for a long time in a brake system of a medium-large vehicle.

1 is a view showing a drum manufacturing process of the air tank manufacturing process according to the present invention.
Figure 2 is a view showing the manufacturing process of the first cover joggly formed during the manufacturing process of the air tank according to the present invention.
3 is a view showing a manufacturing process of the first cover is bonded sheet during the manufacturing process of the air tank according to the present invention.
Figure 4 is a perspective view showing a drum bonded to the first cover and the second cover on both sides of the manufacturing process of the air tank according to the present invention.
5 is a schematic cross-sectional view taken from AA of FIG. 4.
6 is a view showing a container assembled with a connector during the manufacturing process of the air tank according to the present invention.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting of the invention. In the description, overlapping descriptions of the same parts as the known art may be omitted.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In the present invention, the air tank is a manufacturing process of the drum 10 for receiving the compressed air, a manufacturing process of the hemispherical end cover respectively bonded to the left and right sides of the drum 10, and the end cover is bonded to the produced drum 10 It is made through several processes such as welding process, airtightness test for a predetermined pressure and airtightness of the finished air tank, and cleaning of welding area.

In other words, the manufacturing method of the air tank according to the present invention consists of the manufacturing process of each of the three pieces constituting the air tank and the step of assembling the three pieces.

As the material of the air tank, aluminum alloy is applied, and it is preferable that the aluminum tank is lightweight while having strength enough to flow in and out the compressed air required for braking of a medium-large vehicle.

First, a metal plate made of an aluminum alloy material is prepared to manufacture the drum 10 of the air tank, and then the prepared metal plate is cut into an appropriate length and width according to a design using an auto shearing machine (shearing process). A plurality of holes of a predetermined diameter are processed on one side of the metal plate cut to size using a mold or a laser equipment so that there is no imprinting or burr (BURR).

At this time, the pneumatic pressure of the auto shearing machine is 4 ~ 6㎏ / ㎠, the hydraulic pressure is 30 ~ 40kg / ㎠.

The hole is for drainage and serves as a drain hole for discharging moisture generated while the air is compressed and exhausted in the air tank to the outside.

Next, the metal plate formed with the holes is inserted into a rolling chuck of a rolling machine and rolled into a drum shape. At this time, the hydraulic pressure is about 100 to 120㎏ / ㎠ and the roundness is 4 to 5mm. Keep the horizontal and vertical on and keep the deviation from occurring.

Next, a spatter inhibitor is applied evenly on the front surface of the metal plate rolled in a drum shape to prevent contact of the spatters splashing during direct welding.

After fixing the drum-shaped metal plate coated with the anti-spatter on the drum welder, the horizontal welding area of the metal plate is leveled, the side steps are aligned, and the welding is performed at regular intervals (for example, every 200 mm interval). To perform a joining process of bonding and fixing the position. In the welding process, the pneumatic pressure is 4 ~ 6㎏ / ㎠ and at least three points are welded at least.

After the welding process, the abutted edge of the welded drum-shaped metal plate is welded using a drum woven welder. During the direct welding, the die of the drum woven welder is cleaned first, and then the die is welded so that the straight welded portion of the metal plate is maintained in a straight line. The torch is visually checked and matched to the weld point of the metal plate. At this time, there is no spatter and undercut, and the up / down stroke of the torch is appropriately adjusted for general use.

Here, the operating voltage and current of the drum circumferential welder are 16-18V and 160-180A, respectively, and the gas amount is 15-20 L / min, the forward speed is 500-600 mm / min, and the penetration rate is 70% or more.

Next, the sheet 13 is welded to a drum-shaped metal plate using a drum sheet welder, which is set precisely so as to be parallel to the hole of the metal plate, and overlapped during welding. The part should be about 20 mm. That is, the circumference of the part where the outer periphery of the hole of a metal plate and the surface of the sheet | seat 13 abuts at right angles is welded with the drum sheet welding machine. At this time, there should be no spatter, undercut and welding crack.

Here, the operating voltage and current of the drum sheet welder are 14 to 17 V or 22 to 24 V and 180 to 200 A, respectively, and the gas amount is 15 to 20 l / min.

Before performing the inner painting, first brush the film on the material surface of the drum-shaped metal plate using an airbrush to remove residual foreign matter and welding slag, and remove oil and foreign matter with a cloth so that the applied inner paint does not lift. do.

After the brushing process, the paint is applied in an appropriate amount to the inside of the drum-shaped metal plate using a spray prime (internal coating process). At this time, the operating pneumatic pressure of the spray prime is 2 to 3 kg / cm 2, and the operation is performed while being careful not to let the applied paint flow down.

Through the above process, the drum 10, which is the body of the air tank, is manufactured, and the first cover 11 and the second cover 12, which are end covers mounted on the left and right sides of the drum 10, are as follows. It can be produced by the same process.

First, a metal plate for fabricating the first cover 11 is prepared, and a disc of a predetermined diameter is sheared and cut from the prepared metal plate using an auto shearing machine.

After the metal plate of the cut cover material is blanked and loaded on the forming mold, the cushioning pin is accurately set on the forming die, and hydraulic oil is applied to the cut metal plate of the cut material to perform the forming process.

The metal plate of the end cover material cut in the forming process is formed into a substantially hemispherical dome shape.

Next, a plurality of holes are selectively drilled on the upper end of the hemispherical metal plate using a mold or a laser equipment, and the holes to be drilled are holes for compressed air to flow in and out of the air tank.

Next, the foreign substances and internal oil (for example, the hydraulic oil applied to the metal plate during the forming process) on the hemispherical metal plate are cleanly washed (washing process) so that the coating liquid can be applied well during the subsequent painting process.

Next, an appropriate amount of coating liquid is applied to the inner surface of the hemispherical metal plate using spray prime. At this time, the operating air pressure of the spray prime is 2 ~ 3kg / ㎠, this internal coating process may be performed at the same time as the internal coating process of the above-described drum manufacturing process.

Next, the hemispherical metal plate, which has completed the internal coating process, is washed to be free of internal oil and foreign substances, and the metal plate is used by using a joggling machine so that the hemispherical metal plate can be easily inserted into the drum and matched and fixed. Joggle the bottom of the foam.

The working hydraulic pressure of the joggling machine is 65 ~ 75 ㎏ / ㎠ and it is visually free from deformation.

Applying the anti-spatter to the joggly formed hemispherical metal plate and then welding the sheet 14 to the hole of the metal plate (using a sheet welder), the sheet 14 is correctly set to keep parallel to the hole of the metal plate, During welding, the part overlapping with the metal plate should be about 20mm and there should be no spatter, undercut and welding crack.

The operating voltage and current of the sheet welder are 22 to 26 V and 150 to 180 A, respectively, and the gas amount is 15 to 20 l / min.

After the sheet 14 is welded to a hemispherical metal plate, the spatter around the sheet is neatly removed.

In the present invention, the first cover 11 of the air tank may be manufactured by performing the above process, and the second cover 12 is manufactured through the process described below.

First, a metal plate for fabricating the second cover 12 is prepared, and a disc of a predetermined diameter is sheared and cut from the prepared metal plate using an auto shearing machine.

Next, an appropriate amount of coating liquid is applied to the inner surface of the hemispherical metal plate using spray prime. At this time, the operating pneumatic pressure of the spray prime is 2 ~ 3kg / ㎠, this coating process can be performed at the same time as the internal coating process of the above-described drum manufacturing process.

The spherical anti-spherical metal plate is evenly coated on the whole.

Next, a process for joining and welding the first cover 11 and the second cover 12 to the drum 10 of the air tank will be described.

First, the first cover 11 and the second cover 12 are press-fitted on both sides of the drum 10 in order by using a press-fit jig. The first cover (assembled in consideration of the press-in direction and shape) and molded at the time of joggling forming ( 11) and the jog portion of the second cover 12 to be horizontal to the naked eye. At this time, the working air pressure of the press-fit jig is 4 to 6 kg / cm 2.

Next, the first cover 11 and the second cover 12 are press-fitted using a circumferential welder to prevent the first cover 11 and the second cover 12 pressed into the left and right sides of the drum 10 from being separated. The edges of the drum 10 (connecting portions of the drum and the first cover and the second cover) are circumferentially welded and fixed, but there is no undercut in the welded portion, and the overlap interval is 20 mm or less during welding. At this time, the operating voltage and current of the circumferential welding machine are set to 20 ~ 25V and 190 ~ 230A, respectively, the working gas amount is 15 ~ 20ℓ / min and the rotation speed is 800 ~ 900rpm.

That is, the drum 10, the first cover 11 and the second cover 12 are accurately set on the chuck CHUCK of the press-fit jig, and the press-fit operation is carried out, and the first cover 11 press-fitted into the drum 10 is carried out. ) And the second cover 12 are welded so as not to be separated.

Next, the spatters formed on the weld surfaces of the drum 10, the first cover 11, and the second cover 12 are removed. In other words, by removing the spatter of each welding site and the seat thread area using a chisel and an awl so that the coating film is not peeled off during the coating due to the spatter.

Next, a sheet tapping process of tapping and correcting the weld deformed thread of the sheet is performed to ensure there is no deformed thread.

In an embodiment of the present invention the sheet consists of a nut with a thread formed therein.

Airtightly assemble the airtight bolts to the seat to prevent air leakage, and then a drum (hereinafter referred to as a container) in which the first cover 11 and the second cover 12 are welded to a leak test device. After filling the container with air at 10 kg / cm 2, test for air leakage without leakage for about 120 seconds. For airtightness, visual inspection is performed to determine the appearance of fine soapy water bubbles during the test.

After the leak test, wait until the air filled in the air tank-shaped container is discharged and visually check. Then, the airtight bolts are disassembled to open the seat.

Next, clean the inside of the container that passed the leak test using an air inhaler. At this time, the air inhaler is operated to inhale foreign matter at 8 ~ 10 kg / ㎠ pneumatic.

Next, the cleaning and protector process is performed to wipe off and remove foreign substances on the outside of the container, and then cover the sheet using a rubber cap (rubber cap), and hooks to the center and top of the container and hang it on the conveyor.

Then, in order to paint the inside and outside of the container, the conveyor passes the coating device by drying, wherein the heat transfer degree of the coating device of the drying furnace is 200-220 ° C., and the powder soil output is 2-3 kg / cm 2. Powder coating is sprayed uniformly on the inner surface and outer surface of the container with the speed of the conveyor for conveyance of 900 ps. A container coated with an appropriate amount of powder coating is passed through a drying furnace.

Visually inspect the container for which the painting process has been completed and if not found, attach a caution label to the designated surface of the container. The thickness of the container coating film measured using the coating film measuring instrument is expressed in a unit of μm on the cushion label, which is about 60 to 120 μm.

Next, by assembling the connector 15 to the seat 14 of the first cover 11 on the basis of the steering angle using an air impact and a spanner, various parts such as valves, switches, and plugs to be connected to the container, that is, the air tank. To be assembled. When assembling the connector 15, consider the direction and angle, and assemble while paying attention to the damage of the connector.

Next, fill the container with assembled connector 15 with air at least about 10㎏ / ㎠ and apply soapy water to the connector assembly site, and performs a leak test for 2 minutes to visually check whether fine bubbles are generated. That is, the leak test device is used to check for air leakage at the connector assembly site for 120 seconds at about 10 kg / cm 2 or more of pneumatic pressure.

The air tank manufactured as described above is selectively shipped by satisfying the inspection criteria (for example, appearance and dimensions).

While the invention has been shown and described with respect to preferred embodiments thereof, the invention is not limited to these embodiments, and various modifications may be made by those of ordinary skill in the art to which the invention pertains. It includes all forms of embodiments.

10: drum
11: first cover
12: second cover
13,14: Sheet
15: connector

Claims

Preparing a metal plate for fabrication of the drum,
Processing the prepared metal plate into a drum shape in which a plurality of holes are drilled,
Fixing the sheet by welding the hole in the drum-shaped metal plate,
Brushing the surface of the metal plate on which the sheet is welded,
A drum manufacturing process consisting of applying a coating liquid to an inner surface of a brushed metal plate;
Preparing a metal plate for manufacturing the first cover,
Molding the prepared metal plate into a hemispherical shape in which a plurality of holes are drilled,
Applying a coating liquid to the inner surface of the hemispherical metal plate,
Joggling a painted hemispherical metal plate,
Manufacturing a first cover comprising a step of welding the sheets to the holes of the joggly-formed metal plate and removing the spatters around the welded sheet;
Preparing a metal plate for fabricating the second cover;
Molding the prepared metal plate into a hemispherical shape,
Applying a coating liquid to the inner surface of the hemispherical metal plate,
Manufacturing a second cover comprising a step of joggling a painted hemispherical metal plate;
Pressing and fixing the first cover and the second cover manufactured in the manufacturing process of the first cover and the second cover, respectively, on the left and right sides of the drum manufactured in the manufacturing process of the drum,
And circumferentially welding edges of the drum into which the first cover and the second cover are press-fitted to form a container having an air tank shape.

The method according to claim 1,
The step of processing the prepared metal plate into a drum shape with holes,
Cutting the metal plate to a predetermined size and punching holes in one side thereof;
Rolling the metal plate into a drum shape;
Applying a spatter inhibitor to the metal plate wound in a drum shape;
Aligning and welding the side steps of the woven welding portion of the metal plate coated with the anti-spatter;
A method of manufacturing an air tank, comprising the steps of welding the circumferential welded portion of a welded metal plate to a drum shape.

The method according to claim 1,
Coating the powder coating by passing the container through a coating device by drying the paint, assembling the connector to a sheet of the container coated with the powder coating, filling the container with air, and performing a leak test to Checking the airtight state, the method of manufacturing an air tank further comprising the step of removing and cleaning the foreign matter inside the container passing the leak test.

The method according to claim 1,
The inner coating of the first cover and the second cover is a method of manufacturing an air tank, characterized in that at the same time to apply a coating liquid to the inner surface of the brushed metal plate during the drum manufacturing process.

The method according to claim 1,
The method of manufacturing an air tank further comprises the step of removing foreign substances and oil by washing the hemispherical metal plate coated with the coating liquid.

The method according to claim 1,
And removing the spatters formed on the weld surfaces of the drum, the first cover and the second cover.

The method according to claim 1,
And tapping and correcting the weld deformed thread of the sheet.

The method according to claim 1,
And attaching a cushion label on the surface of the container coated with the powder coating to indicate the thickness of the container coating film.