RU2813727C1 - Device for manufacturing welded polyhedral piles and method for their manufacture - Google Patents

Abstract

FIELD: welding technology.

SUBSTANCE: invention relates to fixtures and devices for manufacturing, assembly, and welding of metal products. A method for manufacturing welded polyhedral piles involves manufacturing a pile body from rolled sheets by bending. The locking elements are installed, fixed and secured to the pile body by welding. At least two devices are installed along the length of the pile. Each device contains clamps equipped with hinged eyes and connected to each other by a screw tie. The pile body is installed on the mounting plate with the bottom part. Locking elements are installed on the end faces of the pile body. Using a screw tie of the devices, the distance between the clamps is set in accordance with the current position of the locking elements. The locking elements are fixed on the end faces of the pile body with clamps. The design distance is set between the locking elements. The locking elements are welded to the body of the pile. The pile is cooled in the air to a temperature of the welds and heat-affected zone not exceeding 200 °C.

EFFECT: minimized deformation of the pile during welding.

1 cl, 3 dwg

Description

The invention relates to fixtures and devices for the manufacture, assembly and welding of metal products, facilitating the work of the assembler by ensuring the design dimensions, tolerances and quality of manufacture of metal products by ensuring a tight fit between the welded parts and minimizing deformations of the products during welding.

Currently, for the production of U-shaped cylindrical and multifaceted ones, a technology is used with separate production of the sheet pile body and locking elements, followed by welding them into a single whole. To ensure a tight fit between the parts and high-quality welding, special clamping devices and clamps are used. To avoid deformation of the pile after welding, mechanical straightening is used in roller leveling machines and presses, and also to increase the rigidity and design dimensions of the pile, special metal plates are placed in the internal cavity of the pile, which significantly increases the cost of production.

A clamping device is known (RF patent 2020050, IPC V25V5/02). The device contains two clamps, each of which is made in the form of a rod, two jaws installed on it and a clamping screw installed on one of the jaws; the jaw of one of the clamps has a socket in which the rod of the other clamp is placed. The nest of the jaw of one of the clamps is made in the form of a hole of rectangular cross-section, the axis of which is perpendicular to the rod of the same clamp, and both jaws of each clamp are made movable relative to the rods, equipped with transverse grooves that fix the jaws. The device can be used for assembling and welding metal products.

The disadvantage of the known technical solution is that the device does not prevent deformation of metal products during welding and cannot be used for assembling and welding metal polyhedral piles.

A clamp is known (RF patent 2335388, IPC B23Q3/06). The clamp contains an upper half-bracket connected to an upper support foot facing inside the half-bracket, and a lower end with a lever forming a lower half-bracket connected to a lower plate facing inside the half-bracket, a handle for clamping the half-brackets, and the axes of the clamp parts are connected by parallel hinges. The clamp is made of four parts, and the lever consists of a hollow body, inside of which a pin is coaxially installed, containing an axis fixed at its upper end, on which the upper half-bracket is mounted with the lower end, while the ends of the axis are placed with the possibility of movement in grooves made in the walls of the hollow of the body along it, at the lower end of the finger there is a thread on which a handle is installed, connected to the hollow body by ring elements that provide the possibility of rotating the handle without axial movement, and the axis of connection of the lever with the lower heel is installed at its upper end. The clamp is designed to press the punch to the matrix in the manufacture of fiberglass products.

The disadvantage of the known technical solution is that the device does not prevent deformation of metal products during welding and cannot be used for assembling and welding metal polyhedral piles.

The invention is known according to RF patent 2090348, IPC V25B5/02. A clamp containing a U-shaped body with two shelves and a crossbar, the cross section of the body is made in the form of an I-beam with two parallel walls of equal width and one wall perpendicular to them, a threaded bushing installed on the first shelf, a power screw with a head, a handle in the head and a clamping fifth, a support heel installed on the second shelf coaxially with the power screw. Along the central longitudinal axis of the parallel walls of the I-beam along the outer and inner perimeter there are threaded holes for fastening the limiting support strip; the diameters of the support and clamping heel, the threaded bushing for the power screw and the screw head are made equal to or less than the width of the parallel walls of the I-beam, on one of the outer sides of the parallel The wall of the I-beam is marked with a measuring scale, and on the perpendicular wall of the I-beam, in the corners of the polygon, digital values of the angles are marked. The invention is intended for assembling and welding metal products with different fixed angles between parts of the product.

The disadvantage of the known technical solution, as in previous technical solutions, is that the device does not prevent deformation of metal products during welding and cannot be used for assembling and welding metal polyhedral piles.

The technical result of the invention consists in high-quality welding of the body of a multifaceted pile with locking elements, ensuring their alignment with the end parts of the pile body, ensuring design dimensions and manufacturing tolerances, as well as minimizing deformation of the pile during welding.

This technical result is achieved by the fact that the device for manufacturing welded polyhedral piles contains clamps equipped with eyes with a hinged connection, which are connected to each other by a screw tie.

Also, the technical result is achieved by the fact that the method of manufacturing welded polyhedral piles includes manufacturing a pile body from rolled sheets by bending, installing, fixing and fastening the locking elements to the pile body using welding, while at least two devices are installed along the length of the pile for manufacturing welded multifaceted piles, the pile body is installed on the mounting plate with the bottom part, after which locking elements are installed on the end faces of the pile body, the distance between the clamps is set using a screw tie device in accordance with the current position of the locking elements and the locking elements are fixed on the end faces of the pile body with clamps, then, using screw ties, the design distance between the locking elements is set and the locking elements are welded to the body of the pile, after which, without removing the devices, the pile is cooled in air to a temperature of the welds and the heat-affected zone of no more than 200°C, after which the devices are removed from the pile .

The production of welded polyhedral piles includes the production of a pile body from sheet metal by bending, installation, fixation and fastening of locking elements to the pile body using welding.

The manufacturing process of sheet piles is performed as follows.

The design of the device for welding multifaceted piles is illustrated by drawings, which show:

Fig. 1 – general view of the device for welding polyhedral piles with stepped locking elements (option 1);

Fig. 2 - general view of a device for welding polyhedral piles with straight locking elements (option 2);

Fig. 3 – general view of multifaceted piles with straight locking elements (before welding).

1, 14 – welded polyhedral pile;

4, 5, 17, 18 – locking elements of the pile;

6, 7, 19, 20 – end faces of the pile;

8, 21 – pile body;

27, 28 – bottom part of the pile;

2, 3, 15, 16 – clamps;

9, 10, 22, 23 – clamp eyes;

11, 24 – screw tie;

12, 13, 25, 26 – hinges of screw ties;

29, 30 – mounting plate;

31, 32, 33, 34 – mounting plates.

The device (Fig. 1, option 1) for the production of welded polyhedral piles 1, contains clamps 2, 3 for fixing the stepped locking elements 4, 5 of the pile 1 relative to the end faces 6, 7 of the body 8 of the pile during welding. In this case, the clamps 2, 3 on opposite sides of the body 6, 7 of the pile 1 are equipped with eyes 9, 10 and are connected to each other by a screw tie 11 with hinges 12, 13 at its ends. The centers of the axes of the hinge joints of the clamp 2, 3 on the opposite end faces of the body 6, 7 of the pile 1 are on a line perpendicular to the axis of the pile 1 (taking into account an error of ±3º).

The device (Fig. 2, option 2) for the manufacture of welded polyhedral piles 14 contains clamps 15, 16 for fixing the straight locking elements 17, 18 of the pile 14 relative to the end faces 19, 20 of the body 21 of the pile during welding. In this case, the clamps 15, 16 on the opposite end faces 19, 20 of the body of the pile 21 are equipped with eyes 22, 23 and are connected to each other by a screw tie 24 with hinges 25, 26 at its ends. The centers of the axes of the hinge joints of the clamp 15, 16 on the opposite end faces 19, 20 of the body 21 of the pile 14 are on a line perpendicular to the axis of the pile 14 (taking into account an error of ±3º).

The manufacture of welded polyhedral piles 1, 14 includes the manufacture of pile bodies 8, 21 from sheet metal by bending, installation, fixation and fastening of locking elements to the pile body using welding.

The manufacturing process of sheet piles is performed as follows.

Along the length of the pile, at least two devices are installed for the production of multifaceted piles, while the body of the pile is installed on the mounting plate 29, 30 with the bottom part 27, 28, after which locking elements 4 are installed on the end faces 6, 7, 19, 20 of the body , 5, 17, 18, set the distance between the clamps 2, 3, 15, 16 using a screw tie 11, 24 in accordance with the current position of the locking elements and fix the locking elements 4, 5, 17, 18 on the end faces 6, 7 , 19, 20 of the pile body with clamps 2, 3, 15, 16, then set the design distance (B) between the locking elements using screw ties 11, 24 and weld them to the pile body, after which, without removing the devices, the pile is cooled to air until the temperature of the welds and heat-affected zone does not exceed 200°C (to prevent cracking of the welds), remove the devices from the pile and send it for control measurements and tests. Installation (Fig. 3) of straight locking elements 17, 18 on the end faces 19, 20 is carried out between plates 31, 32, 33, 34, welded with an assembly weld to the internal and external surfaces of the end faces 19, 20. After welding the pile, plates 31, 32, 33, 34 are removed.

As a result of the implementation of the invention, high-quality welding of the body of a multifaceted pile with locking elements is ensured, ensuring their alignment with the end parts of the pile body, design dimensions and tolerances for the manufacture of piles are ensured, and deformation of the pile during welding is minimized.

The invention makes it possible to significantly reduce the labor intensity and cost of manufacturing U-shaped polyhedral piles, improve their quality, and also reduce metal consumption for the manufacture of piles.

Claims (1)

A method for manufacturing welded polyhedral piles, including manufacturing a pile body from sheet metal by bending, installing, fixing and fastening locking elements to the pile body by welding, while at least two devices are installed along the length of the pile, each of which contains clamps equipped with eyes with a hinged connection and connected to each other by a screw tie, the pile body is installed on the mounting plate with the bottom part, after which locking elements are installed on the end faces of the pile body, the distance between the clamps is set using a screw tie of the devices in accordance with the current position of the locking elements and the locking elements are fixed on the end faces of the pile body with clamps, then set the design distance between the locking elements using screw ties and weld the locking elements to the pile body, after which, without removing the devices, the pile is cooled in air to a temperature of the welds and heat-affected zone of no more than 200°C , after which the devices are removed from the pile.