RU2501635C1 - Method of assembly and mill for assembly of i-beam by welding - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to method and mill for production of welded I-beam. Proposed method allows the welding of four-flange seams by argon arc in one pass. Proposed mill comprises bed 1, hydraulically driven rolls 2 with reversible electric drive for setting and centring of beam wall and fitting the beam to welding start position, clamping rolls 3 to centre top flange relative to beam wall, welding heads 5, main hydraulic clamp 6 with roller, bridge 7, supports 8, 10 with hydraulic drives to mounting welding heads, inlet roll table 9, electrically driven propulsor 11 composed of pull roller with drive motor 12. Governor 14 is connected in main motor circuit to control pull roller shaft rpm, that is, the welding rate.

EFFECT: higher quality, longer life of beam drive, expanded range of products.

6 cl, 4 dwg

Description

The invention relates to mechanical engineering, in particular, to welding production.

Known methods of assembly by welding I-beams:

1) a method including assembling a T-beam for tacks, tilting a T-beam, installing a second shelf and assembling an I-beam for tacks for subsequent transfer of the assembled I-beam to a stock or stocks for the final welding of an I-beam, usually setting the beam in position at 45 degrees for welding with the so-called “into the boat” weld, and tack welding is carried out in a carbon dioxide environment, and welding in a boat is electroslag submerged arc welding;

2) the method including assembling the I-beam immediately to the “tack”, for subsequent transfer of the assembled I-beam to the stock or stocks for the final welding of the I-beam, usually by setting the beam in the 45-degree position for welding with the so-called “boat” weld, moreover, tack welding is carried out in a carbon dioxide environment, and welding in a boat is electroslag submerged arc;

3) the method including, the joint assembly and final weld, the execution of the final weld electroslag submerged arc welding in the vertical position of the T-beam wall, tilting of the T-beam, installing it on the second shelf and the execution of electroslag submerged welds for welding joints connecting the second shelf with the wall of the beam, thus obtaining, in two passes, a fully welded I-beam.

All methods are usually carried out on automated assembly mills.

A known mill for assembly by welding an I-beam (see, for example, www.yumtek.ru, a mill for assembly by welding an I-beam on tack model LK ZLJ). This mill includes a bed, a portal with an upper hydraulic clamp, equipped with a roller, an input roller table with hydraulic pressure rollers for installing the beam wall, an output roller table, hydraulic pressure rollers for installing the beam shelf, the main traction roller for moving the beam during tack welding, the electric drive of the main traction roller , frequency regulator of this electric drive, 2 welding machines for automatic welding, 2 calipers with welding heads, hydraulic cylinders for moving calipers and control management executive mill mechanisms.

The assembly process is as follows.

The first shelf prepared in sizes along the width, saber, and non-flatness of the first shelf is placed on the input roller table, the beam wall is installed with the crane on the shelf, the wall with the shelf is tacked manually in 2 points, the tee is installed in the initial position for welding, transferred the machine is in the automatic mode and according to the commands programmed in the controller for this beam, they weld with tacks of 2 waist seams of the first shelf with the wall of the beam, while during welding the brands move slowly, and m The tack is fast by adjusting the speed of rotation of the electric drive with a frequency controller. Welding is carried out in a carbon dioxide environment. Then the brands are turned over and installed on the second shelf in the inlet conveyor, manually tack at the same point on the beam wall with the second shelf, set the beam in the initial position for welding and weld with the tack of the 2 remaining waist seams. Assembly by welding a 2-tee beam is completed.

Next, the beam is moved to the slipway-tilter, where it is installed at an angle of 45 degrees and electroslag welding is performed under flux welding of all 4 waist welds with the joint leg necessary for this particular beam in one or several passes. Welding of 4 waist seams is carried out sequentially on one slipway or in parallel on several slipways. At the same time, welding is carried out on several slipways if it is necessary to obtain the maximum productivity of the beam manufacturing line. Sequential welding minimizes floor space. In this case, the assembly mill operates cyclically, and the final welding jig is continuous.

There are several drawbacks to this method we called the 1st method and the mill.

1.1. Assembly-welding is carried out in 2 passes, and this allows you to have a mill productivity 2 times less than with the simultaneous assembly-welding of all 4 waist welds.

1.2. Assembly-welding is carried out on tacks i.e. not a continuous, but intermittent weld, this reduces the quality of the weld, as compared to welding the weld when the weld is continuous and the weld root is welded, in which the further implementation of the main weld allows you to get a high-quality weld and avoid weld defects caused by lack of penetration of the root of the seam, such as non-penetration, undercut, crater, etc.

1.3. Since welding with tacks is carried out so that during welding the beam should move slowly (with welding speed), and between tacks - quickly (10 times faster) to ensure maximum productivity of the mill, the drive mechanisms of the mill "work in a" torn "mode, and this significantly reduces the resource of their work and leads to more frequent (than with smooth operation at the same speed) repairs and replacements of these mechanisms.

1.4. Since welding is carried out in a carbon dioxide environment, the possibility of welding alloy steels and non-ferrous metals and their alloys is excluded.

A known method and a mill for assembly by welding an I-beam (see, for example, www.stankomax.ru a CNC mill for automatic assembly and tack SKHZ-B).

This mill includes a bed, a portal with an upper hydraulic clamp, equipped with a roller, an input roller table with hydraulic pressure rollers for installing the beam wall, an output roller table, hydraulic pressure rollers for installing the lower beam shelf, hydraulic pressure rollers for installing the upper beam shelf, the main traction roller beams during tack welding, electric drive of the main traction roller, frequency regulator of this electric drive, 2 welding machines for automatic welding, 4 calipers with welding heads, pneumatic cylinders for moving calipers and a controller for controlling actuators of the mill.

The assembly process is as follows.

On the input roller table they place the first shelf prepared in sizes by width, saber and non-flatness on the input shelf, install the beam wall on the shelf with a crane, tack the wall with the shelf manually in 2 points, then place the upper beam shelf on the tee with a crane and tack the upper flange manually in 2 points, set the I-beam to the initial position for welding, put the mill in automatic mode and, according to the commands programmed in the controller for this beam, weld simultaneously rihvatkami 4 waist flange joints with beam wall, wherein during welding of I-beam moves slowly, and between tack quickly by controlling the electric motor drive shaft rotation speed of the traction roller frequency regulator. Welding is carried out in a carbon dioxide environment. Assembly by welding an I-beam is completed.

Next, the beam is moved to the slipway-tilter, where it is installed at an angle of 45 degrees and electroslag welding is performed under flux welding of all 4 waist welds with the joint leg necessary for this particular beam in one or several passes. Welding of 4 waist seams is carried out sequentially on one slipway or in parallel on several slipways. In parallel, on several slipways, welding is carried out if it is necessary to obtain the maximum productivity of the beam manufacturing line. Sequential welding minimizes floor space. In this case, the assembly mill operates cyclically, and the final welding jig is continuous.

There are several drawbacks to this 2nd method and mill that we called.

2.1. Assembly-welding is carried out on tacks i.e. It is not a continuous but a weld, which reduces the quality of the weld compared to weld when the weld is solid and the weld root is welded, in which the further main weld allows a high-quality weld and avoids weld defects caused by lack of penetration of the root of the seam, such as non-penetration, undercut, crater, etc.

2.2. Since welding with tacks is carried out so that during welding the beam should move slowly (with welding speed), and between tacks - quickly (10 times faster) to ensure maximum productivity of the mill, the drive mechanisms work in a “torn” mode, and this is significantly reduces the resource of their work and leads to more frequent (than with smooth operation at the same speed) repairs and replacements of these mechanisms.

2.3. Since welding is carried out in a carbon dioxide environment, the possibility of welding alloy steels and non-ferrous metals and their alloys is excluded.

A known method and a mill for assembly by welding an I-beam (see, for example, www.yumtek.ru universal assembly mill model HW HNX).

This mill includes a bed, a portal with an upper hydraulic clamp, equipped with a roller, an input roller table with hydraulic pressure rollers for installing the beam wall, an output roller table, hydraulic pressure rollers for installing the beam shelf, the main traction roller for moving the beam during welding, the electric drive of the main traction roller, frequency regulator of this electric drive, 2 welding machines for automatic welding, 2 calipers with welding heads, hydraulic cylinders for moving calipers, units and feed mechanisms and "suction" of the flux and the controller for controlling the actuators of the mill.

The assembly-welding process is as follows.

The first shelf prepared in sizes along the width, saber, and non-flatness of the first shelf is placed on the input roller table, the beam wall is installed with the crane on the shelf, the wall with the shelf is tacked manually in 2 points, the tee is installed in the initial position for welding, transferred the machine is in the automatic operation mode and according to the commands programmed in the controller for this beam, they immediately perform final submerged welding of 2 waist welds of the first shelf with the beam wall. Then the brands are turned over and installed on the second shelf in the inlet conveyor, manually tack at 2 points of the beam wall with the second shelf, the beam is set to the initial position for welding and the remaining 2 waist welds are submerged. Welding is carried out in the vertical position of the beam wall, i.e. welding of fillet welds is performed. The assembly and welding of the I-beam is completed.

There are several drawbacks to this 3rd method and mill that we called.

3.1. Assembly-welding is carried out in 2 passes, and this allows you to have a mill productivity 2 times less than with the simultaneous assembly-welding of all 4 waist welds.

3.2. In this method, electroslag welding is performed under the flux of fillet welds, and the maximum leg of the weld when welding “into the corner” under the flux is 9 millimeters, which limits the thickness of the walls or shelves being welded to 14 millimeters (leg = thickness / 2 + 2 mm, see GOST 14806-80), and with the required wall and shelf thicknesses from 6 to 40 mm, this significantly limits the possibilities of the method for the final manufacturing of an I-beam at least in 2 passes without further use of the final welding of waist welds “into a boat”.

3.3. Since welding is carried out under flux, the possibility of welding non-ferrous metals and their alloys is excluded.

There is a method and a mill for assembly by welding an I-beam (see, for example, “Nikolaev G.A. et al., Calculation, design and manufacture of welded structures. A manual for engineering universities, M., 1971, pp. 388 ... 398) selected by us as a prototype.

The prototype shows an automated line for the manufacture of welded I-beams.

As part of this line, there is a mill for assembly by welding I-beams.

The mill is a horizontal conductor with a length equal to the length of the assembled beam. This jig provides the following. The wall of the beam (prepared to the required size) comes from the feeder and horizontally stacks on the magnetic table of the conductor, the shelves of the beam (pre-processed by planing or milling at the place of their contact with the wall in the central part) are installed vertically in the conductor and are pressed against the wall by pneumatic clamps. The beam is assembled for subsequent assembly by welding. Since the elements of the beam (shelves and wall) are pressed with the necessary force for subsequent welding to each other, and during the welding process they will be subjected to thermal stresses, in order to reduce the resulting thermal stresses and warping, it is necessary to weld from the center of the beam to its edges. Therefore, the mill provides mobile portals that can be moved from the center to the edges with 4 electric arc welding machines.

After the assembly of the beam is completed with clamps, an electric current is supplied to the welding machines and, according to the commands of the control equipment, they move with the portals along the beam, electric arc welding “into the corner” of 2 waist welds (top) is made with a continuous filament weld. After performing these seams, the beam is assembled. Pneumatic clamps release it, and it is fed to the first of 4 stocks, where it is laid at an angle of 45 degrees for final welding “in a boat”. On each slipway, one of the 4 waist welds is welded. The performance of the assembly and welding mill and the slipway is synchronized in time so that the manufacturing process of beams is continuous at a high speed.

The method and the prototype mill have several disadvantages.

4.1. Since from the 4 waist seams in the mill only 2 top seams are welded, the assembled beam always has a skew of the shelves relative to the wall, which is fixed during the final welding of all waist seams by “boat” welding, this is corrected in the “mushroom” correction mill , by creating additional stress in the welds, which adversely affects the strength of the manufactured beams.

4.2. Since the assembly before welding is performed so that the shelves are pressed against the wall along the entire length, it becomes necessary to treat the shelves in the central part to fit them tight enough to the wall to avoid gaps that can adversely affect the quality of the weld, i.e. there is a “superfluous" technological operation with the use of "extra" equipment with a corresponding increase in the cost of manufacturing the beam.

4.3. Performing pneumatic (hydro) clamps of the shelves to the wall along the entire length causes the bulkiness and high metal consumption of the clamps and the mill as a whole, and this is the complexity of the repair and the increased cost of the mill and, accordingly, the manufacture of the beam.

4.4. The clamping of the shelves along the entire length necessitates welding from the center to the edges, this leads to the use of 2 portals diverging from the center for the welding heads, complicates the mill, complicates its maintenance and repair, and accordingly increases the cost of manufacturing the beam, compared to machines having one fixed portal.

4.5. The implementation of welds by electric arc welding causes the manufacture of beams only from steel, mainly low-carbon structural, and makes it impossible to manufacture beams from alloy steels, non-ferrous metals and their alloys.

The objective of the proposed invention is to eliminate the disadvantages of analogues and prototype.

This problem is solved by the fact that:

- assembly-welding of an I-beam is made in one pass;

- assembly-welding of an I-beam is made by continuous welds;

- assembly-welding of an I-beam is made by argon-arc welding;

- during assembly-welding, simultaneous welding of 4 waist welds is performed by “angle” welding (2 ceiling and 2 horizontal welds);

- the mill for assembly-welding is made in the form of a bed with a fixed portal installed on it;

- the mill has an input and output roller tables;

- the mill is equipped with an electric drive mover made in the form of a main traction roller for moving (feeding) the beam relative to the welding heads in the process of assembly-welding;

- the mill is equipped with a system of hydraulic press rollers for installing and moving the beam shelves and hydraulic rollers with a reversible electric drive for moving the wall and the beam itself in the process of its preliminary assembly and preparation for subsequent automatic welding;

- the mill has electrical equipment for automatic and, if necessary, manual control of the actuators of the mill;

- the mill is equipped with 4 calipers for welding torches with hydraulic drives for their movement during adjustment and supply of torches to the welding zone;

- the main hydraulic clamp of the mill is equipped with brackets for installing 2 upper supports for welding torches and 2 hydraulic clamping rollers for centering the upper shelf;

- the mill is equipped with 4 welding machines with 4 welding torches for performing argon-arc welding;

- the mill is equipped with a programmable logic controller that provides control electric signals to the actuators of the mill according to a given program for the assembly-welding of the beam.

The technical nature of the alleged invention is illustrated by graphic images.

Figure 1 shows a General view of the mill for assembly by welding an I-beam.

Figure 2 shows a General view of the mill, showing 4 welding torches, the main traction roller, the main hydraulic roller, hydraulic pressure rollers for installing the beam shelves relative to the wall and the cabinet of electrical equipment.

Figure 3 depicts a General view of the mill, showing the input roller table with 3 pairs of hydraulic rotary rollers with reversible electric drive.

Figure 4 shows a General view of the mill, showing it in the process.

The numbers in the figures are indicated.

1. Bed.

2. Hydraulic swivel rollers with reversible electric drive for installation and centering of the beam wall, as well as for setting the beam in the position of the beginning of welding.

3. Hydraulic press rollers for centering the upper shelf relative to the beam wall.

4. Top welding heads.

5. The main hydraulic clamp with a roller.

6. The portal.

7. Calipers with hydraulic drives for installation of the upper welding heads.

8. Entrance roller table.

9. Calipers with hydraulic drives for installation of the lower welding heads.

10. Electric propulsion device made in the form of a traction roller.

11. The main motor of the drive of the traction roller.

12. Argonodutovye welding machines.

13. The output roller table.

14. A frequency regulator included in the circuit of the main electric motor, which, by changing the frequency of the electric current, controls the frequency of rotation of the shaft of the main electric motor (traction roller), thereby regulating the feed speed of the beam, i.e. welding speed.

15. The microswitch unit provides control of the frequency regulator, i.e. setting the welding speed.

16. The mechanism of reversing the rotation of the shaft of the main electric motor.

17. The logical controller provides the supply of control electrical signals to the actuators of the mill in accordance with a given program, if necessary (switching to another frame size of the beam) can be reprogrammed.

18. Electrical cabinet with remote control.

19. Hydraulic press rollers for centering the lower shelf relative to the beam wall.

20. Lower welding heads.

The mill works as follows.

The lower shelf of the beam is laid on the input roller 8 by the workshop crane and fed into the portal 6 until it is gripped (for centering) by the lower hydraulic press rollers 19. Then the wall of the beam is fed by the crane and the wall is aligned using hydraulic reversing rollers with reversible electric drive 2 and align the edges of the wall and lower shelf. 2 tacks are made by hand welding, slightly fixing the wall relative to the lower shelf.

Then, the upper shelf is laid on the wall with a crane so that it is captured by the upper hydraulic press rollers 3 and the edges of the upper shelf and the beam walls are aligned. 2 manual tacks of the upper shelf with the wall are made by welding and the shelf is pressed by the main hydraulic clamp 5 to the wall and lower shelf. Using a mover 10 (roughly) and hydraulically turning rollers 2, the beam is set (precisely) to the position of the start of welding (to the zero point). Using hydraulic calipers 7 and 9, welding heads 4 and 20 are brought into the welding zone. In accordance with the calculated welding speed, its value is set by microswitches 15, thereby setting the frequency of the electric current, which the frequency regulator 14 must provide on the windings of the electric motor 11.

The logic controller 17 is pre-programmed to run the assembly-welding program of this particular beam.

The control panel of the control cabinet 18 sets the automatic mode of operation and starts the start.

The welding machines 12 supply electric current to the welding heads 4 and 20, the electric motor 11 rotates the traction roller of the mover 10, the manufactured beam moves uniformly relative to the welding heads. This is the assembly-welding of the beam from the zero point to its end. The beam, oriented by the pinch roller system, is moved by the mover 10 through the portal 6 until the welding of continuous waist seams along its entire length is completed. At the end of welding, the beam is moved from the input roller table 8 to the output roller table 13. From the roller table 13, the assembled beam is fed to the final welding stocks. As a rule, the final welding is carried out by the so-called “boat welding” method.

Welding parameters are previously calculated by the welder technologist. This allows you to set the welding current on the welding machines 12 and at a given welding speed to set the minimum allowable by the strength condition when transporting the beam from the mill to the final welding stocks, weld leg.

Calipers 7 and 9 are equipped with hydraulic actuators, which allow during the debugging process to adjust the position of the welding heads 4 and 20 for a specific (maybe from 6 to 40 mm) beam wall thickness. Fix this position and when the mill is turned on, the welding torches are connected to the welding zone automatically according to the commands of the controller 17.

The calipers 7 are mounted on the brackets of the main hydraulic clamp 5. This allows you to automatically track the height of the wall of the manufactured beam, which can vary from 200 to 2000 mm. The magnitude of the stroke of the rod of the hydraulic cylinder of the main hydraulic clamp 5 allows you to adjust it to different heights of the walls of the manufactured beam.

The hydraulic press rollers 3 and 19 are equipped with hydraulic cylinders, allowing them to be reconfigured to various shelf widths from 150 to 800 mm. The hydraulic press rollers 3 are mounted on the brackets of the main hydraulic press 5 to ensure their automatic installation on the height of the manufactured beam.

Hydraulic swivel rollers 2 provide a rotation of the "flags" in which they are fixed 90 degrees to freely place the beam shelves on the roller table 8. In the working position, they are pressed against the wall of the beam and provide its predetermined position relative to the shelves.

Thus, the alleged invention allows to provide a multifaceted (5 in one) technical result:

- to improve the quality of welding of the manufactured beam by welding the root of the weld, with the most high-quality argon-arc type of welding;

- to improve the quality of the manufactured beams by eliminating distortions of the beam elements relative to each other;

- increase the durability of the drive of the beam mover, by eliminating the "torn" (fast, slow) operating modes;

- to increase the productivity of the mill, by conducting simultaneous welding of 4 waist welds;

- increase the range of manufactured products by providing the possibility of welding (argon-arc) beams of various metals, such as carbon steel, alloy steel, stainless steel, non-ferrous metals and their alloys.

List of sources of information.

1. Website www.yumtek.ru.

2. Website www.stankomax.ru

3. Nikolaev G.A. and others. Calculation, design and manufacture of welded structures. Textbook for engineering universities, M., 1971

Claims (6)

1. A method of manufacturing a welded I-beam, including installing shelves and beam walls in the mill, pressing the shelves to the beam wall with hydraulic clamps of the shelves, tacking the shelves to the wall and welding the welds of the walls with the beam shelves into the boat, characterized in that the shelves are tacking to the wall is carried out manually with the fixing of the wall first relative to the lower shelf, and then the upper shelf, while the installation of the shelves and the beam wall is done to ensure that the welding torches have access to all 4 waist welds of the beam at the same time, and then first and they perform argon-arc welding at the same time of all 4 waist welds with continuous “filament” welds “into the corner”, and then transport the beam from the mill to the slipway or slipways and perform the final welding of the beam by welding the waist welds “into the boat”, while “filament” welds are performed in such welding modes, in which the dimensions of the legs of these joints provide strength to the beam when it is transported from the mill to the slipway or slipway and tilting during the final welding of the beam by "boat" welding, and when welding in the “corner” and “into the boat” the beam is moved relative to the welding heads with the help of an electric drive mover made in the form of a traction roller. 2. A method of manufacturing an I-beam according to claim 1, characterized in that the shelves and walls of the beam, which are made of carbon structural steel, are welded. 3. A method of manufacturing an I-beam according to claim 1, characterized in that the shelves and walls of the beam, which are made of alloy steel, are welded. 4. A method of manufacturing an I-beam according to claim 1, characterized in that the shelves and walls of the beam, which are made of stainless steel, are welded. 5. A method of manufacturing an I-beam according to claim 1, characterized in that the shelves and walls of the beam, which are made of non-ferrous metals or their alloys, are welded. 6. A mill for manufacturing a welded I-beam, containing a bed, adjustable hydraulic clamps of the upper and lower shelves to the beam wall, input and output live tables and welding machines with welding heads for welding the beam shelves with the wall, characterized in that it is provided with a portal with the main hydraulic clamp of the upper shelf to the wall and to the lower shelf installed in it during the welding process, an electric drive with a frequency regulator to move the beam relative to the welding head made in the form of a traction roller, 4 calipers with hydraulic drives, on which 4 welding heads are mounted, a micro switch made with the possibility of setting a predetermined feed speed of the beam for welding, a mechanism for reversing rotation of the electric drive mover and a logic controller configured to supply control electric signals to the mentioned mechanisms of the mill, while the welding machines are made in the form of devices for argon-arc welding, two of the four mentioned calipers are installed are mounted on the bed, and the other two calipers are mounted on the main hydraulic clamp, and the input roller table is equipped with at least 3 pairs of hydraulically turning rollers with reversible electric drive in each pair to move the beam wall relative to the shelves when they are installed relative to each other and when the beam is installed in the position of the start of welding, and the bed is equipped with a pair of hydraulic clamping rollers for centering the lower shelf relative to the wall and a pair of hydraulic clamping rollers for centering on the main hydraulic clamp top shelf relative to the wall.

Images