RU2478460C1 - Universal tube assembly production unit - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to mechanised welding of metal hardware including custom equipment and may be used for repair of tubes dismantled from main lines for reuse. Proposed unit is equipped with, at least, one moving support 4 and roller rotation drive 2 at tracks 1 and stationary operational unit. Roller rotation drive self-propelled bogie 2 composed of lifting platform is mounted on driven wheels. Two pairs of drive rollers are mounted on said platform for tube assembly 12 and provided with geared motor drive and tube transverse adjustment mechanism. Swinging thrust rollers allow tube assembly to be pressed there against in lifting said platform. Stationary operational unit 3 allows bogie of rotation drive 2 to run there through on track and is provided with working sliding platforms to accommodate processing equipment. Welding set is mounted at operation unit top part.

EFFECT: expanded operating performances.

3 cl, 12 dwg

Description

FIELD OF THE INVENTION

The invention relates to the field of welding production, in particular to universal installations for the manufacture of tube assemblies, and can be used in the manufacture of tube assemblies of various grades of steel and metals, mechanized welding of metal equipment, including non-standard equipment, with which the productivity of the welding process is increased and quality of welded joints during the installation of technological pipelines in the construction and repair of energy facilities, oil and gas processing and chemical pro production, sea and pipeline transport, for example pumping, gas pumping and gas distribution stations and engineering networks in the field and workshop conditions, as well as repairing pipes dismantled from main pipelines for secondary use.

State of the art

Known rotator for welding tubular products containing a bed and mounted on it a two-roller drive mechanism and a clamping device, while the clamping device is made in the form of a portal with a movable traverse mounted on the frame by means of movable supports in a plane perpendicular to the axes of the drive rollers, with the possibility of alternating rotation around one of the axes of the movable bearings located parallel to the axes of the drive rollers, while the drive mechanism is mounted on a movable traverse of the portal.

Power cylinders are mounted on the rotor bed, each of the portal's movable supports is made in the form of a crank shaft rigidly connected to the corresponding portal strut, and the shaft crank is pivotally connected to one of the said power cylinders (see AS SU No. 1339000, class B23K 37/04, published on 09/23/1987).

The disadvantages of this rotator are the design complexity, large dimensions and the number of nodes and devices, the inability to use in the presence of factory pipe insulation and in the field.

Known roller bearings and roller rotators for automatic welding of several types: ESAB 3-500 and ESAB 5-500 for various diameters, mainly for cylindrical products, while the ESAB - S series rotator has a pressure roller that mechanically clamps the product to the drive rollers, it is designed for pipes of small diameters and mainly for drills (see ESAB catalog. Automatic welding. Optional equipment, 2009, p. 36).

The disadvantage of these roller bearings and roller rotators is the need for a jib crane for supplying a welding head for welding under a flux layer to a weld located on the tube assembly, due to which the dimensions of the tube assembly are limited by the dimensions of the jib crane, and also the inability to work in the field.

A clamping and rotating device according to the principle of clamping rollers is known, which comprises a bed, which is a solid-wall structure in which the electrical control and the tipping mechanism drive are located. Tipping is done manually by the crank handle. An electric motor tipping mechanism is also possible. The tipping part consists of a drive and roller boxes, a clamping column, a clamping lever and a clamping roller. The device without tipping is made with the type names U 150H, U 500H, U 1000H (see VIETZ clamping-and-turning device according to the principle of clamping rollers. Product catalog, Pocket Edition Vietz Pipline Equipment 2008, 3Rc.96-97).

The disadvantage of this device is the direct contact of the clamping roller with the surface of the pipe, which limits its use in cases with pipes with a factory insulating coating, while the diameter range does not exceed 800 mm.

Known designs of end rotators: the T-25 M manipulator and special welding devices for pipe structures and tanks based on fastening in a faceplate such as a turning cartridge for the open end of a pipe or pipe assembly (see Welding equipment. Directory, part two. Institute of Electric Welding E.O.Patona, ed.Navukova Dumka, 1988, p. 262).

The disadvantage of this type of rotators is that when changing the diameter to be welded to the tube assembly on the end rotator, it is necessary to tune the rotation of the rotator in order to ensure the linear welding speed specified by the technological mode, while the roller rotator according to the invention provides regardless of the diameter of the tube assembly the same linear speed specified by the technological mode. The end rotator does not have the ability to fasten to the end of the pipe assembly closed by the pipe part (fitting), and therefore the number of welded joints on the pipe assembly made by mechanized welding methods decreases, these joints increase the number of joints performed on the construction site using manual arc welding in fixed position, for the possibility of welding such a joint on the end rotator, it is necessary to create and use special equipment, its use requires significant costs and all omogatelnogo time. When using an end rotator for cutting pipes and welding pipe assemblies to move along the assembly from joint to joint, it is necessary to specially arrange a “garland” of cables, wires and hoses that ensure the operation of welding equipment, mechanisms and the supply of working and dangerous combustible gases, as well as a mobile portal , jib cranes and other equipment for supplying equipment and tools for cutting and welding that moves with the “garland” to the work area, while using a stationary operating box according to the proposed acquisition (see figure 3) eliminates the need to move the "garland" and mechanisms for adjusting welding equipment when changing the diameter of the tube assembly, since the thrust rollers according to the invention are at a constant upper level and any node regardless of diameter comes to this level, necessary for establishing an automatic machine for welding under a flux layer.

The closest in technical essence and the achieved positive effect and accepted by the authors for the prototype is the Kudryavtsev manipulator for welding pipe assemblies, including a roller rotator, welding equipment, a power source, the operation of which is based on pressing the tube assembly with the upper linkage roller to the lower rollers using compressed air (see A.N. Batenchuk “Production and installation of technological pipelines”, published by the Literature on construction, M., 1971, p. 116).

The disadvantages of this Kudryavtsev manipulator are that all the rollers are made of metal with a notch, which excludes the use of the manipulator in the manufacture of pipe assemblies with an anti-corrosion coating, and a jib crane is required to feed the welding head for welding under the flux layer to the weld located on the pipe assembly therefore, the dimensions of the tube assembly are limited by the dimensions of the jib boom crane, and with each change in the diameter of the tube assembly it is necessary to change the height of the boom of the mechanism on which welding head, and adjust its installation, while the manipulator is installed on the foundation, there are no rail tracks for additional supports, if necessary it works on a long tube assembly, its range of operation is limited to a tube assembly diameter of 400 mm, a constant supply of compressed air is required for operation , the manipulator is not adapted to work in the field, and also has low productivity and inconvenience to the operator in work.

Disclosure of invention

The task of the invention is to develop a universal installation for the manufacture of tube assemblies, which, rotating the tubular assembly of complex configuration (see Fig. 4, 5, 6, 7, 8, 9, 10, 11, 12), makes it possible to use high-performance and high-quality methods mechanized welding in the manufacture of piping assemblies for various branches of industrial construction in the field and workshop conditions, with a sharp decrease of up to 40-60% of pipe joints made by manual arc welding by professional welders in fixed floors It can occur at construction sites during the installation of technological pipelines and replaced by a welder-operator who welds on a rotating pipe assembly with pipe parts (bends, tees, transitions, plugs), and which displaces the main volumes of manual arc welding of lower productivity and with great influence “Human factor” on the quality of welded joints, as well as having ease of use and a reduction in the cost of construction and installation works.

The technical result that can be obtained using the present invention is reduced to the ability to weld products in a wide range of diameters and thicknesses, high quality of the welded joint, the mechanized process of manufacturing tube assemblies of various configurations, including joints with two or more factory shaped parts, high performance, the possibility of readjustment and adjustment, ease of use and reduce the cost of construction works.

The technical result is achieved using a universal installation for the manufacture of tube assemblies, containing a roller rotator, a welding machine, a power source, while the installation is equipped with rail tracks, an operating box, at least one movable support-lunette, while installed on rail tracks a roller rotator, at least one movable support-lunette, and in the middle of the rail tracks above them a stationary operating box, and the roller rotator is made in the form of self-propelled trolley, consisting of a lifting platform mounted on drive wheels with a drive mechanism for the wheels, while the lifting platform is equipped with a lifting mechanism up and down the platform with two pairs of drive drive rollers located on it, with a mechanism for lateral adjustment of drive drive rollers depending on the diameter of the machined products and a gear motor for driving the drive rollers with the possibility of installation on the last tubular assembly, while on the self-propelled trolley mounted turnstile thrust rollers with a mechanism the lapel, and the operating box is made with the possibility of placing processing equipment on it and consists of working sliding platforms with the ability to perform work operations, while in the upper part of the operating box there is a welding machine for welding under the flux layer, and on its sides there are stairs and a working a place for the operator with a workplace adjuster.

In the installation, the up-down lifting mechanism of the lifting platform is made hydraulic or mechanical.

In the installation, driving drive rollers are made rubberized.

Brief Description of the Drawings

Figure 1 is given a universal installation for the manufacture of tube assemblies, a General view.

Figure 2 is the same as a roller rotator.

Figure 3 is the same operating box.

Figure 4 - characteristic pipe nodes representative, performed on a universal installation for the manufacture of pipe nodes, tap-transition ring-pipe (pipe).

Figure 5 - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, bend-adapter ring-pipe-adapter ring-bend.

Figure 6 - characteristic pipe nodes-representatives, performed on a universal installation for the manufacture of pipe nodes, branch-pipe-branch.

In Fig.7 - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, pipe-pipe-pipe.

On Fig - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, pipe-branch-transition-plug.

In Fig.9 - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, branch-pipe-tee-pipe-adapter ring-tee.

Figure 10 - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, plug-adapter ring-tee-adapter ring-tee-adapter ring-tee-adapter ring-plug.

In Fig.11 - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, branch-pipe-tee-pipe-tee-pipe-pipe-transition-plug.

On Fig - characteristic pipe nodes representatives, performed on a universal installation for the manufacture of pipe nodes, non-standard equipment.

The implementation of the invention

A universal installation for the manufacture of tube assemblies consists of rail tracks 1, which are two rails fixed to sleepers (not shown), and a roller rotator 2, an operation box 3 and a movable support-rest 4, which are a rolling trolley with a height-adjustable and center-to-center distance roller support, wherein the roller rotator 2 is made in the form of a self-propelled trolley consisting of a lifting platform 5 mounted on drive wheels 6 with a mechanism 7 of the wheel drive 6, and the lifting platform 5 is equipped with a hydraulic (or mechanical) mechanism 8 for lifting up and down the platform 5, with two pairs of rubberized drive rollers 9 located on it, with a lateral adjustment mechanism 10 of the drive rollers 9, adjustable in speed by the drive (gear motor) 11 depending on the diameter of the processed products with the possibility of installation on the drive drive rollers 9 of the tube assembly 12, and the rotation speed of the drive pair of drive rollers 9 has a continuously adjustable working also marching speed, while the lifting platform 5 with drive driving rollers 9 before working occupies the initial lower position 13, and during operation - the working upper position 14, pressing the tube assembly 12 against the turning thrust rollers 15 with the lapel mechanism 16 mounted on a self-propelled truck , while the operating box 3 is placed above the rail tracks 1 with the possibility of entry into it and the passage of the inner roller rotator 2 with the product, the tube assembly 12 and the movable support-rest 4 in the form of a rolling trolley, while the fixed operating box 3 is arranged to accommodate all processing equipment (not shown) and tool (not shown) on it at a constant level, while operating box 3 consists of working sliding platforms 17, 18, 19, on which all the necessary processing equipment is located and a tool for performing work operations in the most convenient position for a given type of work with various types of equipment and tools, for example, an operation for welding a root seam necessary to be able to perform I have automatic welding of the same seam, they are performed from a pull-out platform 19 by manual arc welding or semi-automatic in a shielding gas environment, fire cutting, gas or plasma, is performed from site 17, and the mechanical cleaning of edges after cutting is performed from site 18, and in the upper part operating box 3 has a welding machine 20 for welding under the flux layer, and above the operating portal 3 with the help of frames 21, a tent 22 is fixed to protect from adverse weather conditions when using the installation in the field, and on the sides of the operating portal 3 are stairs 23 and a workstation 24 for the operator with a regulator (not shown) of the workplace 24, while the movable support-lunettes 4, depending on the size and configuration of the processed or manufactured product, one or two can be installed on one or two sides of the roller rotator 2, on the tube assembly 12 there is also shown a joint 25 requiring automatic welding, and a joint 26 made by automatic welding using a welding machine 20 for welding under a flux layer.

Universal installation for the manufacture of tube assemblies works as follows.

To install a universal installation for the manufacture of tube assemblies in the field, they select a site, prepare a crushed stone base, block it, for example, with road plates without slopes, lay rail sections with sleepers, receiving rail tracks 1, and a roller rotator 2 and a movable support are mounted on them lunette 4, which, depending on the size and configuration of the processed or manufactured product, can be installed one or two on one or two sides of the roller rotator 2, and in the middle of the rail stroke In the first way 1, a stationary operating box 3 is installed above them, onto which, using the frames 21, a tent 22 is fixed to protect from adverse weather conditions when using the installation in the field, and on the sides of the operating box 3 there are ladders 23 and a workstation 24 for the operator, then on a roller rotator 2, which is made in the form of a self-propelled trolley, consisting of a lifting platform 5, mounted on drive wheels 6 with a mechanism 7 for driving wheels 6, with two pairs of drive rubber located on it of the drive rollers 9, on which the tube assembly 12 is mounted, and with its considerable length, two support-rests 4 in the form of a rolling trolley are used, while the turn-on thrust rollers 15 are 90 ° turned away (see figure 2) a position parallel to the axis of the installation, and the drive rollers 9 of the lifting platform 5 and the rollers of the support-rest 4 are in the lower position (see figure 1 and figure 3), while the welder-operator, while in the workplace 24 , using the control panel, gives the command to the roller rotator 2 to move along the rail tracks 1 into the working space of the operating box 3, which it carries out using the drive wheels 6 with the mechanism 7 of the wheel drive 6, and after entering the operating box 3 of the first joint 25, to be welded, stops the roller rotator 2, while the flap stop rollers 15 are rotated 90 ° perpendicular to the axis of the installation, and the lifting platform 5 with the drive rollers 9 lifts the tube assembly 12 and presses it against the flap stop rollers 15 with a force that ensures uniform rotation of the tube assembly 12, while the rollers of the support-lunette 4 simultaneously rise to such a level as the driving rollers 9, provide a strictly horizontal position of the tube assembly 12, and the above operations to press the tube assembly 12 to the flap stop rollers 15 and raise the supports -brooks 4 can be made immediately after installing the tube unit 12 on the roller rotator 2 until the tube unit 12 is inserted into the working space of the operating box 3, and a particularly valuable feature of the universal installation that distinguishes it from all other types of installations is the possibility of a roller rotator 2 with of the lifting platform 5, bring the tube assembly 12 to a constant level of the flap thrust rollers 15, and therefore there is no need to adjust the height of the welding machine 20 for welding under the flux layer (see figure 3).

The next step, the welder-operator turns on the roller rotator 2 and the drive rollers 9 provide the rotation of the tube assembly 12 with the speed necessary for the process, and the welder-operator, together with the assistant, performs welding of each layer according to the procedure provided for by the process chart, after welding of the first joint of the joint is completed 25, the welder-operator turns off the rotation of the drive rollers 9, turns on the movement of the roller rotator 2 towards the operating box 3, removing the finished or finished joints 26 (see Fig. 1) from the workspace of the box 3, introducing into it the next joint 25, repeating these operations until the welding of all joints 25 on the pipe assembly 12 is completed, while after removing the pipe assembly 12 from the working space of the operating box 3, the lifting platform 5 is lowered, the flap persistent rollers 15 using the mechanism 16 lapels are turned 90 °, setting parallel to the axis of the universal installation, the finished tube assembly 12 is removed from the roller rotator 2 and the next tube assembly 12 to be welded is mounted on it, while the roller rotator 2 moves in the opposite direction thoron first joint 25 of the next spool 12 is introduced into the working zone operating box 3, and all operations are repeated.

The installation of a universal installation for the manufacture of tube assemblies in workshop conditions is similar to the field one, and rail tracks 1 are installed near one of the walls, while the stationary operating box 3 focuses on itself all the cables, combustible and inert gases, water and air, if necessary, introduced from below by metal tubes, saving the installation from bulky and dangerous “garlands” inherent to other types of installations, and they can easily be removed from the operating box zone 3 during ongoing technological processes in dividing overlap "glare" caused by welding. The installation can be integrated into any production line. The installation according to the invention improves the level of industrial safety, environmental friendliness and production culture.

The universality of the installation lies in the fact that in field welding of pipe assemblies 12 of any size along the length, the length of the rail tracks 1 increases, it also allows you to sharply increase the number of welded joints 26 on the pipe assembly 12, especially in the field, by extending the rail track 1 to the required dimensions of the dimensions of the tubular assembly 12, increases the number of joints 25 performed by a high-performance mechanized welding method, as well as all related operations associated with the manufacture of pipe knots, such as: cutting, heating before welding, edge preparation, and so on, in addition, it is possible to produce tube assemblies 12 and equipment from various grades of steel and metals, including the following typical for a universal installation for the manufacture of tube assemblies representative pipe assemblies (see FIGS. 4, 5, 6, 7, 8, 9, 10, 11, 12):

- bend-adapter ring-pipe (pipe);

- bend-adapter ring-pipe-adapter ring-bend;

- branch-pipe-branch;

- bend-pipe-bend;

- bend-pipe-transition-plug;

- branch pipe-pipe-tee-pipe-adapter ring-tee;

- plug-adapter ring-tee-adapter ring-tee-adapter ring-tee-adapter ring-cap:

- bend-pipe-tee-pipe-pipe-tee-pipe-transition-plug

as well as work on mechanized welding of longitudinal and circumferential welds of equipment, including non-standard equipment, to repair pipes dismantled on main steel pipelines for their secondary use.

Due to the large gap in the minimum and maximum diameters of the tube assemblies 12 to be manufactured DN = 200-1400 mm and cutting the pipes to reduce the stroke of the hydraulic and mechanical lifting mechanisms 8 and sliding platforms 17, 18, 19, it is necessary to divide the plants into several types into groups diameters, where the first group and, accordingly, the installation for diameters DN = 200, 300, 350, 400, 500, 600 mm, the second group for diameters DN + 700, 800, 900, 1000, 1200, 1400 mm, which will reduce the dimensions and metal consumption of the plants and will make them more convenient for transportation in case of left-handed and more compact for use in the workshop, the installation can be made for diameters less than DN = 200 mm or for one diameter, including for special steels and non-ferrous metals, where it is possible to expand the capabilities of the working space of the operating box 3.

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

- high productivity of the welding process and the quality of welded joints;

- saving resources and time for auxiliary operations;

- the manufacture of pipe assemblies of almost any configuration of the same type, with a sequential division into standard production operations, which positively affects both the speed of manufacture and the quality of the welded joint;

- welding technology on a rotating pipe assembly not only eliminates the most defective sections of welded joints (ceiling position when making the root of the seam), but also performs the entire root layer in one most convenient position, which positively affects the quality of the root seam and the weld as a whole ;

- the installation is convenient for disassembling - assembling and transportation by separate units and assemblies, it is completed from several ready-made sections of rail tracks assembled together, a roller rotator, an operating box and a fixed support-rest, while all these nodes are located on a 12-meter platform of the car length meter;

- convenience and safety at work.

Claims (3)

1. Installation for the manufacture of tube assemblies, containing a roller rotator, a welding machine and a power source, characterized in that it is equipped with at least one movable support-lunette and a roller rotator, made with the possibility of their placement on rail tracks, and stationary operating box, while the roller rotator contains a self-propelled trolley in the form of a lifting platform mounted on drive wheels, and two pairs of drive drive rollers mounted on it mounted on it of them of a manufactured tube assembly having a drive with a gear motor and a mechanism for their lateral adjustment depending on the diameter of the pipes of the manufactured assemblies, while the self-propelled cart has flap thrust rollers with the possibility of pressing the tube assembly to them when lifting the platform, the operating box is installed with the possibility of passage through it along the rail tracks of the carriage of the rotator and has working retractable platforms for placing processing equipment on them, stairs installed along its lateral sides m, and adjustable workstation for the operator, and automatic welding machine is installed at the top of the operating box. 2. Installation according to claim 1, characterized in that the platform lifting mechanism is made hydraulic or mechanical. 3. Installation according to claim 1, characterized in that the drive drive rollers are made rubberized.

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