RU2321481C2 - Method of and plant for continuous manufacture of tubular wire skeleton - Google Patents

Abstract

FIELD: mechanical engineering.

SUBSTANCE: invention can be used in production of carrying members of filters, fittings of metal-plastic pipes, spatial reinforcement members of reinforced concrete articles, etc. According to proposed method, wire spiral is uniformly wound at preset pitch on longitudinal wire members arranged uniformly over circumference of mandrel and is welded by roller electrode with crossed over longitudinal wire members in process of winding. Position of electrodes is adjusted by opposite longitudinal displacement. Speed of displacement is adjusted continuously either manually, or automatically. Automatic adjustment is done taking into account readings of support electrode wear sensor connected through feedback with electrode shifting mechanism.

EFFECT: provision of stability of diameter over length of skeleton at its manufacture, reduced labor input, provision of high accuracy of skeleton diameter, stable strength of welded joints over length of skeleton.

3 cl, 5 dwg

Description

The technical field to which the invention relates.

The invention relates to welding production, in particular to a method for the continuous manufacture of a tubular wire frame and installation for its implementation. The frame can be used as load-bearing elements of various filters, reinforcement of metal-plastic pipes, spatial reinforcing elements of reinforced concrete products, etc.

State of the art

A device for manufacturing reinforced thermoplastic pipes is known, comprising a worm press with an extrusion straight-through head, a feed mechanism for longitudinal and transverse metal fittings and a spiral generator, while the device is equipped with an assembly for welding metal fittings mounted on an extrusion head.

In the device, the welding unit is made in the form of a ring fixed to the extrusion head and a roller mounted on the faceplate, which is equipped with a rotation drive relative to the longitudinal axis of the extrusion head.

In the device, the ring is made on the outer surface with longitudinal grooves for reinforcement with a depth equal to half the thickness of the reinforcement.

In the device, the spiral generator is rigidly fixed to the faceplate and made in the form of a sleeve with internal threading (see USSR AS No. 657997, class B29D 23/05, B29F 3/00, publ. 04.25.1979).

The disadvantage of this device is that when winding the transverse reinforcement, it is necessary to rotate it around the mandrel, since the latter is stationary, which implies the finiteness of the transverse reinforcement, determined by the capacity of the rotating bobbin, as a result of which it is impossible to ensure the pipe formation process is infinite.

A known method of manufacturing a polymer reinforced pipe, comprising feeding longitudinal and transverse reinforcement to the mandrel and rigidly fastening them at the intersection with subsequent pouring of the reinforcement with thermoplastic material, while the endless transverse reinforcement is preliminarily formed, imposed on it and the longitudinal reinforcement is rigidly fastened with it, and then in a spiral, the reinforcement is wound onto a rotating mandrel and the turns of the reinforcement are rigidly fastened along the edges with the formation of a tubular frame, after which the frame is filled thermoplastic material (see US Pat. RF No. 2065118, CL F16L 9/12, publ. 08/10/1996).

The disadvantage of this method is the low productivity and quality of the reinforced pipe.

The closest in technical essence and the achieved positive effect and adopted by the authors for the prototype is a method for continuous manufacture of a tubular wire frame and installation for its implementation, which consists in the fact that longitudinal wire elements that are evenly spaced around the circumference of the supporting welding electrode in the form of a mandrel and they are translationally moved relative to it, a wire spiral is wound with a given step, and as it is wound, it is welded with successively crossed longitudinal wire elements with a roller electrode, which is rotated around them, and upon reaching the specified depth of wear of the reference electrode, which is less than the maximum permissible, the position of the welding electrodes is directly adjusted during continuous fabrication of the frame by discrete longitudinal displacement of one of them relative to the other, and the reference electrode is displaced in the direction of movement of the longitudinal wire elements, and the roller electrode in the opposite direction.

In the method, a discrete displacement of the welding electrode is performed in increments of 0.5 ... 1.0 of the diameter of the longitudinal wire elements, the achievement of the specified wear depth of the reference welding electrode is determined by the decrease in the radius of the welded wire spiral.

In the method, achieving a predetermined wear depth of the reference welding electrode is determined by time, a discrete displacement of the welding electrode is performed at predetermined time intervals with a step of 0.1 ... 1.0 of the diameter of the longitudinal wire elements (see US Pat. No. 1815899, cl. B29D 23/00, B23K 11/00, 11/06).

The disadvantage of this method and device for its implementation is the unstable accuracy of the diameter of the frame, the low strength of the welded joints along its length, the high complexity of its manufacture, high consumption of the material of the reference electrode, low productivity of the process.

Disclosure of the invention.

The technical result that can be obtained using the present invention is reduced to the stability of the diameter along the length of the frame during its manufacture, reducing the complexity, high accuracy of the diameter of the frame, which varies depending on the significant wear of replaceable welding electrodes made of expensive materials, stable strength of welded joints along the length of the frame.

The technical result is achieved using a method of continuous manufacture of a tubular wire frame in which longitudinal wire elements arranged uniformly around the circumference of the mandrel with a removable support electrode mounted on it and progressively moved relative to it are wound with a predetermined step and the wire spiral is welded with it as it is wound with sequentially crossed by longitudinal wire elements with a roller electrode, which is rotated around them, and upon reaching a predetermined depth of the nose of the reference electrode, less than or equal to the maximum permissible value, adjust the position of the welding roller electrodes by relative opposing their longitudinal movement, while the speed of movement of the electrodes is continuously controlled directly during the manufacture of the frame or automatically taking into account the readings of the wear sensor of the reference electrode associated with an adjustable positive feedback with a mechanism for moving electrodes, or set in manual mode, depending on the wear rate PORN electrode experimentally measured under specific conditions.

Installation for the continuous manufacture of a tubular wire frame containing a feeding device, a guide rack mounted on a common base with a longitudinal movement mechanism, on which a mandrel is mounted with a supporting electrode fixed to it, having grooves evenly spaced around the circumference for longitudinal wire elements being wound from bobbins, a bobbin with wire for transverse spirals, freely rotating on a drum with a faceplate forcibly rotated by its drive, on which a spiral helix generator of a transverse helix and a roller welding electrode for welding the intersections of the longitudinal and transverse wires, the installation is additionally equipped with a speed controller for continuous oncoming movement of the electrodes, a wear electrode for the reference electrode, an actuator and a communication device, and the speed controller is configured to control signals through the actuator from the wear sensor of the reference electrode, providing tracking the size of the diameter of the welded spiral the frame and mounted on the faceplate, while the said elements are connected by appropriate communication devices.

The installation additionally contains a device for manually setting the speed of mutual uniform counter-movement of the electrodes, depending on the experimentally measured wear rate of the reference electrode.

The essence of the method of continuous manufacture of the tubular cage 1 is that on the longitudinal wire elements 7 located uniformly around the circumference of the mandrel 5, on which is installed a removable supporting electrode 6 with guide grooves of depth t = (0.25 ÷ 0.5) d, where t is the depth of the guide groove of the reference electrode 6; d is the diameter of the longitudinal wire element 7, the wire spiral is wound with a given step and, as it is wound, it is welded with the roller electrode 15 sequentially intersected by the longitudinal wire elements 7, which are rotated around them, and when the specified wear depth of the reference electrode 6 is less than or equal to maximum allowable, they adjust directly in the process of continuous manufacturing of the frame 1 the position of the welding roller electrodes 15 by means of an automatic continuous, connected adjustable by negative feedback with the wear sensor 18 of the reference electrode 6, the counter longitudinal movement of the reference electrode 6 relative to the roller electrode 15 with adjustable speed, while the speed of the counter longitudinal displacement of the welding electrodes relative to each other is set manually depending on the wear rate of the reference electrode 6, measured experimentally under specific conditions.

A brief description of the drawings.

Figure 1 gives a method of continuous manufacture of a tubular wire frame and installation for its implementation, graphs of changes in technological parameters that explain the proposed method in comparison with the prototype.

Figure 2 shows the installation for the continuous manufacture of a tubular wire frame, General view.

Figure 3 is the same, the weld site.

In Fig.4 is the same, the welding unit in Fig.3.

Figure 5 is the same process flow diagram.

The implementation of the invention.

Installation for the continuous manufacture of a tubular wire frame 1 contains mounted with the possibility of longitudinal movement on a common base 2 guide rack 3 with a mechanism 4 for longitudinal movement (electromechanical, hydromechanical or other type), on which a mandrel 5 is mounted with a removable supporting electrode 6 mounted on it with guides grooves with a depth of t = (0.25 ÷ 0.5) d, where t is the depth of the guide groove of the reference electrode 6; d is the diameter of the longitudinal wire element 7 (see FIG. 5) for the longitudinal wire element 7, wound from bobbins 8, on the base 2 there is also a casing 9 with a drum 10 located on it, equipped with a rotation drive (not shown). A freely rotating reel 11 for transverse spirals 12 of the frame 1, a faceplate 13, on which a roller 14 of a helical former of transverse spirals 12, a welding roller electrode 15 connected to an external welding current source (not shown) through contact brushes 16 and a collector ring are mounted on the drum 10 17, and the second pole of the welding current source is connected (not shown) with the reference electrode 6. On the faceplate 13 is also installed a wear sensor 18 (DI) of the reference electrode 6, supported by its measuring probe 19 (for example, in e of a spring-loaded roller) (see FIG. 5) on a turn of a transverse spiral 12, which is already preferably welded around the entire circumference to the longitudinal elements 7. The installation also includes an actuator 20 (electromechanical, hydromechanical or other type) for automatically controlling the regulator 21 (for example, a variator or by another mechanism) the displacement speed of the electrodes and the device 22 (mechanical, hydraulic or other type) of manual installation of the speed of the mutual counter-movement of the electrodes. The controller 21 may be a separate unit or component of the longitudinal movement mechanism 4 (for example, a gearbox with a controlled speed variator (not shown). The above installation elements are connected by appropriate communication devices 23, 24, 25, 26, 27. The installation also includes a feeding device 28 ( for example, caterpillar type) for supplying to the welding zone a longitudinal wire element 7 and the removal of the finished wire frame 1.

A method of continuous manufacture of a tubular wire frame and installation for its manufacture works as follows.

The longitudinal wire element 7 is wound from the bobbins 8, pulled and moved together with the finished frame 1 in the direction of arrow A (see Fig. 2) using a feed device 28 for feeding into the welding zone, while the longitudinal wire element 7 passes along the guide grooves of the support electrode 6. When the drum 10 rotates, the guide roller 14 rotating with it winds onto the longitudinal wire element 7, resting on the support electrode 6, a transverse wire spiral 12, which is wound from the freely rotating bobbin 11, which, as it is wound, welded to a sequentially crossed longitudinal wire element 7 by a roller electrode 15, rotating together with the faceplate 13 mounted on the drum 10. Welding voltage from an external source of welding current is supplied to the reference electrode 6 and through contact brushes 16 and the collector ring 17, isolated mounted on the faceplate 13 , to the roller welding electrode 15. During the welding process, both welding electrodes 6 and 15 undergo wear, upon reaching the limit value of which they are replaced. To compensate for the wear of the reference electrode 6 upon reaching the maximum design depth H of wear of the grooves of the reference electrode, counter-movement is carried out continuously with a constant speed d (Fig. 1) along the axis of the frame 1 of electrodes 6 and 15 by means of a longitudinal movement mechanism 4 connected by a communication device 27 to the roller electrode 15 and a guide post 3 with a reference electrode 6. The speed d of the mutual counter continuous continuous uniform movement of the electrodes when operating in automatic mode is supported by the 21 speed controller of growth, controlled by an actuator 20 for automatically controlling the controller 21 of the speed of movement of the electrodes through the communication device 25 from the signals received through the communication device 24 from the wear sensor 18 of the reference electrode 6, connected through the communication device 23 with a measuring probe 19 that monitors the diametrical size of the transverse wire spiral 12, corresponding to the set wear depth H of the reference electrode 6. When operating in manual mode, the required speed d of the oncoming continuous uniform movement of the ele ktrodov 6 and 15 is installed by the device 22 manual speed setting through its communication device 26.

Figure 1 shows graphs of changes in process parameters explaining the proposed method in comparison with the prototype, in which the solid line shows the changes in the parameters according to the invention, and the dashed line shows the parameters according to the prototype. Wherein:

υ is the mutual reciprocal displacement rate of the electrodes 6 and 15;

to - the number of operations to control the diameter of the frame 1;

n is the depth of wear of the grooves of the reference electrode 6;

i _St - the density of the welding current at the junction reference electrode 6 is a longitudinal wire element 7 of the frame 1;

and - the wear rate of the grooves of the reference electrode 6;

J _St - welding current;

F _to - the contact area of the reference electrode 6 and the longitudinal wire;

τ _cf is the strength of the welded joint;

l is the length of the manufactured frame 1. Thus, in the prototype (see figure 1):

- the speed υ of the relative displacement of the electrodes 6 and 15 periodically along the length of the frame 1 varies from zero to maximum, and the periods of switching on the mechanism are determined by the qualifications and attentiveness of the technological personnel (see graph “a”);

- to determine the moment of the next discrete displacement of the electrodes 6 and 15, the intensity-dependent wear of the reference electrode 6 of the diametric size of the frame 1 is checked, and the number "K" of the required diameter measurements increases with the approach of the moment of the next discrete displacement (see graph "b" );

- the depth “N” of wear of the reference electrode 6, equal to half the minus tolerance on the size of the diameter of the frame 1, varies from zero to “N” along the length of the frame 1 in accordance with the frequency of discrete switching on the displacement of the electrodes 6 and 15, which is the reason for the unstable accuracy of the diameter of the frame 1 along its length (see graph “c”);

- at the beginning of each period of the discrete relative displacement of the electrodes 6 and 15, a multiple increase in the welding current density J _sv occurs due to a decrease in the area “F _k ” of the contact of the longitudinal wire element 7 with the reference electrode 6, which leads to an increase in the wear rate “And” of the reference electrode 6, periodic changes in the welding current J _St , which in turn changes the strength τ _{cf of the} welding joint along the length of the frame 1 (see graphs "g" and "d").

The proposed method allows to obtain stable accuracy of the diameter of the frame 1 and the strength of welded joints along its length, reducing the complexity of its manufacture and consumption of the material of the reference electrode 6, increasing the productivity of the process and eliminating the human factor in the process.

The invention in comparison with the prototype and other known technical solutions has the following advantages:

- stable accuracy of the diameter of the frame and the strength of welded joints along its length;

- reducing the complexity of its manufacture and consumption of the material of the reference electrode;

- increasing the productivity of the process and eliminating the influence of the human factor on the manufacturing process;

- high long-term strength of the reinforced polymer pipe;

- reduction of production costs and additional profit from increasing the service life of pipes.

Claims (3)

1. A method for the continuous manufacture of a tubular wire frame in which longitudinal wire elements arranged uniformly around the circumference of the mandrel with a removable support electrode mounted thereon and progressively moved relative to it are wound with a predetermined step by a wire spiral and, as it is wound, welded it in series intersected by longitudinal wire elements by a roller electrode, which is rotated around them, and upon reaching a predetermined depth of wear of the reference electrode, less than or equal to to the maximum permissible value, the position of the welding roller electrodes is adjusted by their relative counter-longitudinal movement, characterized in that the speed of movement of the electrodes is continuously controlled directly during the manufacturing of the frame or automatically, taking into account the readings of the wear electrode of the reference electrode associated with an adjustable positive feedback with the mechanism for moving the electrodes, or set in manual mode depending on the wear rate of the reference electrode, measured experimentally under specific conditions. 2. Installation for the continuous manufacture of a tubular wire frame containing a feeding device, a guide rack mounted on a common base with a longitudinal movement mechanism, on which a mandrel is mounted with a supporting electrode fixed to it, having grooves uniformly spaced around the circumference for longitudinal wire elements being wound from bobbins , a reel with a wire for transverse spirals, freely rotating on a drum with a faceplate forcibly rotated by its drive, on which it is mounted a helix generator of a transverse helix and a roller welding electrode for welding intersections of a longitudinal and transverse wire, characterized in that the installation is additionally equipped with a speed controller for continuous oncoming movement of the electrodes, a wear electrode of the reference electrode, an actuator and a communication device, and the speed controller is configured to be controlled via an actuator mechanism by signals from the wear sensor of the reference electrode, providing tracking of the size of the diameter of the weld the wound helix of the frame and mounted on the faceplate, while the said installation elements are connected by appropriate communication devices. 3. Installation according to claim 2, characterized in that it further comprises a device for manually setting the speed of mutual uniform oncoming movement of the electrodes, depending on the experimentally measured wear rate of the reference electrode.

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