WO2023115726A1 - 一种载人球形耐压壳焊接工作台及其加工方法 - Google Patents

一种载人球形耐压壳焊接工作台及其加工方法 Download PDF

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WO2023115726A1
WO2023115726A1 PCT/CN2022/081708 CN2022081708W WO2023115726A1 WO 2023115726 A1 WO2023115726 A1 WO 2023115726A1 CN 2022081708 W CN2022081708 W CN 2022081708W WO 2023115726 A1 WO2023115726 A1 WO 2023115726A1
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welding
tooling
support
manned
positioning
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PCT/CN2022/081708
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English (en)
French (fr)
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张建
林泽坤
展铭
赵坦
王芳
李永胜
苏世杰
唐磊平
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江苏科技大学
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Publication of WO2023115726A1 publication Critical patent/WO2023115726A1/zh

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass

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  • the invention relates to welding processing equipment, in particular to a manned spherical pressure-resistant shell welding workbench and a processing method thereof.
  • Submersibles are important equipment for ocean exploration and scientific research, and pressure-resistant balls are one of the important components of manned submersibles. Due to its simple structure and uniform force, the spherical pressure hull has become the first choice for large-depth submersibles. Most deep-sea balls are medium-thick shells, buckling is the main failure mode, and their characteristics are affected by material and geometric defects. Therefore, the design quality and manufacturing accuracy of spherical pressure shells are important guarantees for the performance of submersibles.
  • the pressure-resistant ball is two hemispherical shells welded into a whole ball.
  • the existing hemispherical shell welding fixtures are relatively backward. Larger, so the welding allowance that needs to be reserved is also higher. At the same time, due to the backwardness of the welding process, it is easy to produce waste products during the welding process, resulting in waste of raw materials.
  • the Chinese patent application number 201420748001. problem of instability discloses an automatic butt seam welding fixture for spherical shell components, which can be widely used for welding and clamping of various thin-walled hemispherical shell parts.
  • the Chinese patent with the application number 201810551176.4 discloses a heating pipe welding fixture at the construction site, which solves the problems that there is currently no special fixture for heating pipe welding and the difficulty of welding and fixing during construction operations.
  • a welding fixture for spherical parts with application number 201420748001.X includes pressure jaws, protrusions, brackets, discs, and bolts. The pressure jaw moves up and down through the slot, the position of the pressure jaw is determined according to the size of the part, and then the pressure jaw is fixed by the bolt and the bolt hole, and finally the clamping function of the part is realized.
  • the fixture clamp fixes the parts through the pressing claws, so the tightening effect is poor and the precision is low. Due to the size limitation of its fixture, usually only hemispherical shells with a radius less than 100mm can be clamped. In addition, when the weld is cooled, local shrinkage will occur, which will deform the spherical shell and reduce the overall accuracy and strength. Most of the currently disclosed hemispherical shells produced by other welding fixtures are small-scale industrial hemispherical shells, and the welding deformation cannot be controlled, so they cannot be used as deep submersibles. There are generally four problems in the final induction:
  • the existing fixtures provide clamping force through the jaws, and cannot provide sufficient clamping force when clamping heavy parts. When clamping metal parts with smooth curved surfaces such as spherical shells, sliding or even fall off.
  • the existing fixture tooling usually needs to be manually adjusted when clamping the parts, resulting in an error of about 1 mm to 3 mm when aligning the weld seam, which eventually leads to a large welding error.
  • the existing fixture tooling can only clamp thin-walled hemispherical shells with a fixed radius less than 150mm and light weight, and cannot clamp and weld medium and large thick-walled spherical pressure-resistant shells.
  • the existing fixture tooling cannot control the deformation caused by welding, and cannot control the welding quality, and can only realize a single clamping function.
  • the purpose of the present invention is to provide a manned spherical pressure shell welding workbench, which improves the welding precision of pressure shell welding, enhances the anti-deformation effect, and enhances its applicability. And the processing method of the welding workbench is provided.
  • a manned spherical pressure shell welding workbench including welding tooling components, tooling wheels, sliding brackets, transmission screws, and guide rail tables.
  • there are two driving screws horizontally one end of the two is respectively connected to the opposite sides of the guide rail platform, the other end is respectively pierced in a corresponding sliding bracket and connected to it in rotation, and each sliding bracket is respectively installed with a Tooling wheels, two tooling wheels are arranged at relative intervals, and a welding tooling assembly is respectively installed on the opposite side of the two, and the two welding tooling assemblies are coaxially symmetrical.
  • the welding tooling assembly includes a tooling inner mold and a tooling positioning outer ring.
  • An annular flange is arranged on one side of the outer peripheral surface of the tooling inner mold, and the other side is placed in the tooling positioning outer ring, so that one side of the annular flange is aligned with the tooling.
  • One side of the positioning outer ring is attached, and a circle of fastening bolt holes and a circle of positioning bolt holes are evenly distributed on the outer ring of the tooling positioning from the inside to the outside in sequence, and a circle of positioning bolt holes is evenly distributed on the ring flange.
  • Fastening bolt hole 2 fastening bolt hole 1 corresponds to fastening bolt hole 2 one-to-one and is respectively connected by a fastening bolt and a fastening nut, and a plurality of toolings are evenly distributed on one side of the tooling wheel at corresponding circumferential intervals
  • Positioning holes positioning bolt holes correspond to tooling positioning holes one by one and are respectively connected by a positioning bolt and a positioning nut.
  • the tooling inner mold has a frustum-shaped structure, and its inner ring is provided with a through cavity with a stepped inner wall, and an annular flange is arranged on the outer peripheral surface of one side of the small-diameter inner ring.
  • the guide rail platform includes a base and a slide rail.
  • the base is U-shaped, and two slide rails are installed in parallel on the base at intervals.
  • the bottom is slidably connected with the slide rail, and the transmission lead screw is horizontally spaced above the slide rail, and one end thereof is connected with one side of the base.
  • the sliding support includes a first support, a second support, and reinforcing ribs, the second support is vertically fixed on the first support, and at least one The reinforcing rib and the tooling wheel are vertically placed and installed on the other side of the second support, the bottom of the first support is slidingly connected with the guide rail platform, and the transmission screw is passed through the second support.
  • the tooling wheel is a hollow cylindrical structure, and the two tooling wheels are coaxially symmetrical.
  • a processing method of the above manned spherical pressure shell welding workbench comprising the following steps:
  • the first step Pre-processing to leave a boss on the spherical surface of the hemispherical shell;
  • Step 2 Nest the tooling inner mold on the hemispherical shell for positioning
  • Step 3 Use spot welding to fix the two hemispherical shells with the corresponding welding tooling components
  • Step 4 Install the two welding tooling components on the corresponding tooling wheels
  • Step 6 After the welding is completed, when the sphere is completely cooled down, remove the two welding tooling components from the rail table;
  • Step 7 Remove the tooling inner mold
  • Step 8 Cut off the margin of the spherical boss
  • the welded whole ball is machined, the spherical boss is processed and removed, and finally the whole ball is obtained, and the processing is completed.
  • the advantage of the present invention is:
  • the hemispherical shell forms a wedge-shaped structure with the stepped structure of the inner ring of the tooling inner mold through the pre-processed boss, and then fixes it by spot welding. Then, the tooling inner mold is installed on the guide rail platform and aligned by moving on the guide rail to control the alignment error. Within 1mm, the automatic alignment function is realized.
  • Fig. 1 is the schematic diagram of general assembly of the present invention
  • Fig. 2 is a schematic diagram of an exploded structure of a welding tool assembly
  • Fig. 3 is the structural representation of tooling wheel
  • Fig. 4 is the structural representation of removal tooling wheel of the present invention.
  • Figure 5 is a sectional view of the frock welding
  • Fig. 6 is a welding process flow chart
  • Fig. 7 is a schematic diagram of welding process steps.
  • FIGS. 1-10 A manned spherical pressure shell welding workbench, as shown in FIGS.
  • Sliding support 15 is provided with two relative intervals, and is respectively slidably connected with it on guide rail platform 17, and guide rail platform 17 comprises base 171, slide rail 172, and base 171 is U-shaped, and slide rail 172 is installed with two parallel intervals on base 171.
  • the sliding bracket 15 includes a first support 151, a second support 152, and a reinforcing rib 153.
  • the second support 152 is vertically fixed on the first support 151, and one side of the second support 152 is connected to the first support 151.
  • the bottom of the first support 151 is correspondingly provided with two slide grooves.
  • the slide grooves and the slide rails 172 are correspondingly matched so that the bottom of the slide bracket 15 is slidably connected with the slide rails 172 .
  • each sliding bracket 15 is respectively equipped with a tooling wheel 14, the tooling wheel 14 is vertically placed and installed on the other side of the second support 152, the tooling wheel 14 is a hollow cylindrical structure , two tooling wheels 14 are coaxially spaced symmetrically.
  • the drive screw 16 is externally connected to the motor, and the motor drives the drive screw 16 to rotate, thereby driving the sliding support 15 to move on the slide rail 172, and the alignment of the two tooling wheels 14 is carried out by the slide rail 172 positioning.
  • a welding tool assembly is installed on opposite sides of the two tool wheels 14 respectively, and the two welding tool assemblies are coaxially symmetrical.
  • the welding tool assembly includes a tooling inner mold 1 and a tooling positioning outer ring 3.
  • An annular flange is arranged on the outer peripheral surface of one side of the tooling inner mold 1, and the other side is placed in the tooling positioning outer ring 3, so that one side of the annular flange is aligned with the outer peripheral surface of the tooling positioning outer ring 3.
  • the side of the tooling positioning outer ring 3 is attached, and a circle of fastening bolt holes 9 and a circle of positioning bolt holes 8 are evenly distributed on the tooling positioning outer ring 3 from the inside to the outside in order of circumferential intervals, and the corresponding circumferential spacing is on the ring flange.
  • a plurality of fastening bolt holes 10 are evenly distributed, and the fastening bolt holes 9 correspond to the fastening bolt holes 10 one by one and are respectively connected by a fastening bolt 2 and a fastening nut 7, so that the tooling inner mold 1 It is integrated with the tool positioning outer ring 3, and a plurality of tool positioning holes 5 are evenly distributed on the side surface of the tool wheel 14 at corresponding circumferential intervals.
  • the positioning bolt holes 8 correspond to the tool positioning holes 5 one by one and pass through a positioning bolt 4 and a tool positioning hole 5 respectively.
  • a set nut 6 is connected so that the whole welding tool assembly is installed on the tool wheel 14 .
  • the tooling inner mold 1 has a frustum-shaped structure, and its inner ring is provided with a through cavity with a stepped inner wall, and an annular flange is arranged on the outer peripheral surface of one side of the small-diameter inner ring.
  • the main material of this workbench is 5CrNiMo.
  • the main function of the tooling inner mold 1 and the tooling positioning outer ring 3 is to position the hemispherical shell 11 for splicing and welding, and at the same time prevent the hemispherical shell 11 from being deformed during the welding process.
  • the positioning bolt holes 8 and tooling positioning The function of the hole 5 is to ensure that the welding tool assembly is aligned with the center of the tool wheel 14, thereby ensuring the accuracy of the welding alignment of the hemispherical shell 11.
  • the tooling wheel 14 can rotate on the sliding support 15, and it is convenient to rotate and adjust the welding position in time when welding.
  • the main function of the welding tool assembly is to fix the hemispherical shell 11 .
  • the hemispherical shell 11 and the tooling inner mold 1 are fixed by spot welding at the spot welding zone 12, and the two hemispherical shells 11 are welded at the weld seam 13 to form a whole ball.
  • the above-mentioned processing method of the manned spherical pressure shell welding workbench specifically includes the following steps:
  • the first step Pre-processing to leave a boss on the spherical surface of the hemispherical shell;
  • the pressed left and right hemispherical shells are machined, and a boss is machined at the equator position of the two, which is used to cooperate with the inner mold of the tooling to form a wedge-shaped structure, and at the same time leave a machining allowance for subsequent finishing.
  • Step 2 Nest the tooling inner mold on the hemispherical shell for positioning
  • a tooling inner mold is respectively nested on the two hemispherical shells to form a wedge-shaped structure.
  • the center of the hemispherical shell coincides with the center of the inner mold of the tooling.
  • only the two hemispherical shell toolings need to be docked, which saves the need for alignment of traditional fixtures. This step also improves the alignment accuracy.
  • Step 3 Use spot welding to fix the hemispherical shell and the tooling inner mold
  • Spot welding is used to fix the hemispherical shell and the inner mold of the tooling.
  • the spot welding point is shown as the spot welding area 12 in Figure 5.
  • Fixing the hemispherical shell and the inner mold of the tooling by spot welding not only solves the problem of clamping large and heavy models with traditional fixtures
  • the inner mold of the tooling can also limit the deformation of the metal due to heating and cooling when welding the hemispherical shell, which greatly ensures the overall roundness of the welding sphere.
  • Step 4 Assemble the welding tooling components and install them on the workbench
  • Step 5 Welding is performed along the weld seam 13 .
  • Step 6 After the welding is completed, wait for the sphere to cool down and remove the tooling;
  • Step 7 Remove the tooling inner mold
  • Step 8 Cut off the margin of the spherical boss
  • the welded whole ball is machined, the spherical boss is processed and removed, and finally the whole ball is obtained, and the processing is completed.

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Abstract

一种载人球形耐压壳焊接工作台,包括焊接工装组件、工装轮(14)、滑动支架(15)、传动丝杠(16)、导轨台(17),滑动支架相对间隔设有两个,分别在导轨台上与其滑动连接,传动丝杠水平设有两个,两者的一端分别与导轨台的相对两侧连接,另一端分别穿设于对应的一个滑动支架中并与其转动连接,每个滑动支架上分别安装有一个工装轮,两个工装轮相对间隔设置,两者的相对一侧面上分别安装有一个焊接工装组件,两个焊接工装组件同轴对称。该焊接工作台从根本上解决了传统夹具夹紧球类零件时夹紧力不足或者容易发生脱落的问题,支持大尺寸球壳固定焊接,解决了焊接时发生形变的问题。还涉及一种载人球形耐压壳焊接工作台的加工方法。

Description

一种载人球形耐压壳焊接工作台及其加工方法 技术领域
本发明涉及一种焊接加工设备,尤其是涉及一种载人球形耐压壳焊接工作台及其加工方法。
背景技术
潜水器是大洋勘查与科学研究的重要装备,而耐压球是载人潜水器重要组成部件之一。球形耐压壳因其结构简单,受力均匀等优势,已成为大深度潜水器的首选。深海球多为中厚壳,屈曲是其主要失效形式,其特性受到材料及几何缺陷影响,因此,球形耐压壳的设计质量和制作精度是潜水器性能的重要保证。通常来说,耐压球是两个半球壳通过焊接成一个整球,已有的半球壳焊接夹具工装较为落后,通过其焊接成型的半球壳封头精度较低,且由于焊接造成的形变也较大,所以需要保留的焊接加工余量也较高,同时由于焊接工艺的落后,造成在焊接过程中容易出现废品,导致原材料的浪费。
目前,有关半球壳焊接夹具及工艺方面资料较少,相关典型的技术方案有如下3个:申请号为201420748001.X的中国专利公开了一种球形零件焊接夹具,避免了用人来定位带来的不稳定性的问题。申请号为200820141505.X的中国专利公开了一种球形壳体器件自动对缝焊接夹具,它能广泛用于各类薄壁半球壳形壳体零件的焊接夹紧。申请号为201810551176.4的中国专利公开了一种施工现场通暖管道焊接夹具,解决目前没有通暖管道焊接的专用夹具和施工作业时焊接固定困难的问题。
然而,用于载人深潜器制作的球形耐压壳往往都是中大型半球壳,其不仅体积较大,且重量也十分大,而一般的夹具无法提供足够的夹紧力来固定较大较重的半球壳,且由于其制作精度要求也十分高,因此对焊接精准度以及控制焊接变形有着较高的要求。如申请号为201420748001.X的一种球形零件焊接夹具,包括压爪、卡凸、托架、圆盘、螺栓。压爪通过卡槽上下移动,根据零件的大小确定压爪的位置,然后通过螺栓和螺栓孔对压爪进行固定,最终实现对零件的夹紧功能。该夹具夹通过压爪对零件进行固定,紧效果较差,且精度较低。由于其夹具的尺寸限制,通常只能夹紧半径小于100mm的半球壳。此外,当焊接处冷却后会发生局部收缩,使球壳发生形变,降低整体精度与强度。目前所公开的通过其他焊接夹具工装制作的半球壳大多为小型工业生产半球壳,且不能控制焊接形变,无法作为深潜器所用。最终归纳普遍存在如下四个问题:
1.现有夹具均为通过夹爪提供夹紧力,且当夹紧较重零件时无法提供足够的夹紧力,当夹紧球壳这种表面为光滑曲面的金属零件时会发生滑动甚至脱落。
2.现有夹具工装在夹紧零件时通常需要手动调整,导致对齐焊缝时会产生1mm~3mm左右的误差,最终导致较大的焊接误差。
3.现有夹具工装只能夹紧固定半径小于150mm、重量较轻的薄壁半球壳,无法夹紧焊接中大型厚壁球形耐压壳。
4.现有夹具工装无法控制由于焊接时产生的形变,且无法控制焊接质量,只能实现单一的夹紧功能。
发明内容
发明目的:针对上述问题,本发明的目的是提供一种载人球形耐压壳焊接工作台,提高耐压壳焊焊接精度,增强防变形效果,增强其适用性。并提供了该焊接工作台的加工方法。
技术方案:一种载人球形耐压壳焊接工作台,包括焊接工装组件、工装轮、滑动支架、传动丝杠、导轨台,滑动支架相对间隔设有两个,分别在导轨台上与其滑动连接,传动丝杠水平设有两个,两者的一端分别与导轨台的相对两侧连接,另一端分别穿设于对应的一个滑动支架中并与其转动连接,每个滑动支架上分别安装有一个工装轮,两个工装轮相对间隔设置,两者的相对一侧面上分别安装有一个焊接工装组件,两个焊接工装组件同轴对称。
进一步的,焊接工装组件包括工装内模、工装定位外环,工装内模一侧的外周面上设有环形翻边,另一侧置于工装定位外环中,使环形翻边一侧面与工装定位外环一侧面贴合,工装定位外环上从内至外依次周向间隔均布有一圈紧固螺栓孔一和一圈定位螺栓孔,环形翻边上对应周向间隔均布有多个紧固螺栓孔二,紧固螺栓孔一与紧固螺栓孔二一一对应并分别通过一个紧固螺栓及一个紧固螺帽连接,工装轮一侧面上对应周向间隔均布有多个工装定位孔,定位螺栓孔与工装定位孔一一对应并分别通过一个定位螺栓和一个定位螺帽连接。
最佳的,工装内模为圆台形结构,其内圈设有内壁呈阶梯形的通腔,环形翻边设置于小直径内圈一侧的外周面上。
进一步的,导轨台包括底座、滑轨,底座呈U型,滑轨在底座上平行间隔安装有两条,滑动支架的底部对应设有两道滑槽,滑槽与滑轨对应配合使滑动支架底部与滑轨滑 动连接,传动丝杠水平间隔设置于滑轨上方,其一端与底座的一侧面连接。
进一步的,滑动支架包括第一支座、第二支座、加强筋,第二支座竖直固定于第一支座上,第二支座一侧面与第一支座之间至少设有一个加强筋,工装轮竖直放置安装于第二支座的另一侧面上,第一支座的底部与导轨台滑动连接,传动丝杠穿设于第二支座中。
最佳的,工装轮为镂空的圆柱形结构,两个工装轮同轴对称。
一种上述的载人球形耐压壳焊接工作台的加工方法,包括以下步骤:
第一步:前期加工在半球壳的球面留出凸台;
将压制好的左右两个半球壳进行机加工,在两者的赤道位置分别加工出一道凸台;
第二步:将工装内模嵌套在半球壳上进行定位;
将两个半球壳分别嵌设于一个焊接工装组件上,使他们形成楔形结构,此时半球壳圆心与焊接工装组件圆心重合;
第三步:采用点焊将两个半球壳与对应的焊接工装组件进行固定;
第四步:将两个焊接工装组件分别安装在对应的工装轮上;
第五步:进行焊接;
将左右两个半球壳对接,通过传动丝杠带动工装支架沿着导轨台移动,将两个焊接工装组件相互定位,沿着焊缝进行焊接直至整个球体焊接到位;
第六步:焊接完成后,待球体完全冷却下来,将两个焊接工装组件从导轨台上取下;
第七步:取下工装内模;
使用焊枪加热球面凸台与焊接工装组件焊点固定处,将焊接工装组件取下;
第八步:切除球面凸台余量;
对焊接好的整球进行机加工,将球面凸台加工切除,最后得到整球,加工完成。
有益效果:与现有技术相比,本发明的优点是:
1.紧固效果好。通过将工装内模点焊固定在半球壳上,从根本上解决了传统夹具加紧球类零件时夹紧力不足或者容易发生脱落的问题。
2.实现快速对齐功能,避免手动调整带来的误差。半球壳通过事先加工出的凸台,与工装内模内环的阶梯结构形成楔形结构后点焊固定,再将工装内模安装在导轨台上通过在导轨上移动进行对齐,将对齐误差控制在1mm内,实现了自动对齐功能。
3.支持大尺寸球壳固定焊接。通过取消传统压爪固定方式,引入大尺寸工装内模,可支持固定焊接半径1000mm以下的大型半球壳,解决传统夹具只能夹紧固定半径150mm以内的球壳模型。
4.解决了焊接时发生形变的问题。由于通过工装内模焊固定球壳,在焊接过程中工装内模限制了由于球壳受热或冷却过程中发生的形变。
附图说明
图1为本发明总装示意图;
图2为焊接工装组件的分解结构示意图;
图3为工装轮的结构示意图;
图4为本发明去除工装轮的结构示意图;
图5为工装焊接剖视图;
图6为焊接工艺流程图;
图7为焊接工艺步骤示意图。
具体实施方式
下面结合附图和具体实施例,进一步阐明本发明,应理解这些实施例仅用于说明本发明而不用于限制本发明的范围。
一种载人球形耐压壳焊接工作台,如图1~4所示,包括焊接工装组件、工装轮14、滑动支架15、传动丝杠16、导轨台17。
滑动支架15相对间隔设有两个,分别在导轨台17上与其滑动连接,导轨台17包括底座171、滑轨172,底座171呈U型,滑轨172在底座171上平行间隔安装有两条,滑动支架15包括第一支座151、第二支座152、加强筋153,第二支座152竖直固定于第一支座151上,第二支座152一侧面与第一支座151之间至少设有一个加强筋153,第一支座151的底部对应设有两道滑槽,滑槽与滑轨172对应配合使滑动支架15底部与滑轨172滑动连接。
传动丝杠16设有两个,分别水平间隔设置于滑轨172上方,两者的一端分别与底座171的相对两侧面连接,另一端分别穿设于对应的一个滑动支架15的第二支座152中并与其转动连接,每个滑动支架15上分别安装有一个工装轮14,工装轮14竖直放置并安装于第二支座152的另一侧面上,工装轮14为镂空的圆柱形结构,两个工装轮14同轴间隔对称。传动丝杠16外接电机,电机带动传动丝杠16转动,从而带动滑动 支架15在滑轨172上移动,通过滑轨172定位进行两个工装轮14的对齐。
两个工装轮14的相对一侧面上分别安装有一个焊接工装组件,两个焊接工装组件同轴对称。焊接工装组件包括工装内模1、工装定位外环3,工装内模1一侧的外周面上设有环形翻边,另一侧置于工装定位外环3中,使环形翻边一侧面与工装定位外环3一侧面贴合,工装定位外环3上从内至外依次周向间隔均布有一圈紧固螺栓孔一9和一圈定位螺栓孔8,环形翻边上对应周向间隔均布有多个紧固螺栓孔二10,紧固螺栓孔一9与紧固螺栓孔二10一一对应并分别通过一个紧固螺栓2及一个紧固螺帽7连接,使工装内模1与工装定位外环3连接成一体,工装轮14一侧面上对应周向间隔均布有多个工装定位孔5,定位螺栓孔8与工装定位孔5一一对应并分别通过一个定位螺栓4和一个定位螺帽6连接,使整个焊接工装组件安装于工装轮14上。
工装内模1为圆台形结构,其内圈设有内壁呈阶梯形的通腔,环形翻边设置于小直径内圈一侧的外周面上。通过将半球壳11焊缝周围进行加工出凸台结构,与工装内模1内部阶梯型结构拼装形成楔形结构,能够快速精确的将半球壳11安装在工装内模1上,同时通过焊接将半球壳11固定在工装内模1上。
本工作台的主要材料为5CrNiMo,工装内模1和工装定位外环3的主要作用为定位半球壳11进行拼接和焊接,同时防止半球壳11在焊接过程中变形,定位螺栓孔8和工装定位孔5的作用是保证焊接工装组件与工装轮14的圆心对齐,从而保证半球壳11焊接对齐的精度。
工装轮14能够在滑动支架15上转动,在焊接时方便旋转及时调整焊接位置。
如图5所示,焊接工装组件主要作用为对半球壳11进行固定。半球壳11与工装内模1在点焊区域带12通过点焊进行固定,两个半球壳11通过在焊缝13处进行焊接成整球。
图6、7所示,上述的载人球形耐压壳焊接工作台的加工方法,具体包括如下步骤:
第一步:前期加工在半球壳的球面留出凸台;
将压制好的左右两个半球壳进行机加工,在两者的赤道位置分别加工出一道凸台,作用为和工装内模进行配合形成楔形结构,同时为后续精加工的留出加工余量。
第二步:将工装内模嵌套在半球壳上进行定位;
在两个半球壳上分别嵌套一个工装内模,使其形成楔形结构,此时半球壳圆心与工装内模圆心重合,后续只需将两个半球壳工装进行对接,节省了传统夹具需要对齐这一 步骤,同时也提高了对齐精度。
第三步:使用点焊固定半球壳与工装内模;
采用点焊将半球壳与工装内模进行固定,点焊点位如图5中点焊区域带12所示,通过点焊固定半球壳与工装内模不仅解决了传统夹具在夹紧大型重型模型时夹紧力度不足的问题,同时还可以通过工装内模限制在焊接半球壳时由于金属受热和冷却时产生的形变,极大程度上保证了焊接球体的整体圆度。
第四步:拼装焊接工装组件并安装在工作台上;
将工装定位外环通过紧固螺栓与焊接着半球壳的工装内模进行拼装固定,然后将左右两个半球壳工装通过定位螺栓安装在对应的工装轮上,并通过定位螺帽紧固,同时将压力传感器安装在定位螺栓上,然后通过传动丝杠带动滑动支架移动,使两个半球壳拼装定位,左右两个半球壳的圆心重合,准备焊接。
第五步:进行焊接,沿着焊缝13进行焊接。
第六步:焊接完成后待球体冷却拆除工装;
焊接完成后,待整个球体完全冷却下来,此时球体由于冷却产生的收缩形变被工装内模限制,极大程度上避免了因为形变使球球体圆度下降,最后将焊接工装组件连同球体从工装轮上拆除,然后再拆除工装定位外环。
第七步:取下工装内模;
使用焊枪加热球面凸台与工装内模焊点固定处,将工装内模取下。
第八步:切除球面凸台余量;
对焊接好的整球进行机加工,将球面凸台加工切除,最后得到整球,加工完成。

Claims (7)

  1. 一种载人球形耐压壳焊接工作台,其特征在于:包括焊接工装组件、工装轮(14)、滑动支架(15)、传动丝杠(16)、导轨台(17),滑动支架(15)相对间隔设有两个,分别在导轨台(17)上与其滑动连接,传动丝杠(16)水平设有两个,两者的一端分别与导轨台(17)的相对两侧连接,另一端分别穿设于对应的一个滑动支架(15)中并与其转动连接,每个滑动支架(15)上分别安装有一个工装轮(14),两个工装轮(14)相对间隔设置,两者的相对一侧面上分别安装有一个焊接工装组件,两个焊接工装组件同轴对称。
  2. 根据权利要求1所述的一种载人球形耐压壳焊接工作台,其特征在于:焊接工装组件包括工装内模(1)、工装定位外环(3),工装内模(1)一侧的外周面上设有环形翻边,另一侧置于工装定位外环(3)中,使环形翻边一侧面与工装定位外环(3)一侧面贴合,工装定位外环(3)上从内至外依次周向间隔均布有一圈紧固螺栓孔一(9)和一圈定位螺栓孔(8),环形翻边上对应周向间隔均布有多个紧固螺栓孔二(10),紧固螺栓孔一(9)与紧固螺栓孔二(10)一一对应并分别通过一个紧固螺栓(2)及一个紧固螺帽(7)连接,工装轮(14)一侧面上对应周向间隔均布有多个工装定位孔(5),定位螺栓孔(8)与工装定位孔(5)一一对应并分别通过一个定位螺栓(4)和一个定位螺帽(6)连接。
  3. 根据权利要求2所述的一种载人球形耐压壳焊接工作台,其特征在于:工装内模(1)为圆台形结构,其内圈设有内壁呈阶梯形的通腔,环形翻边设置于小直径内圈一侧的外周面上。
  4. 根据权利要求1所述的一种载人球形耐压壳焊接工作台,其特征在于:导轨台(17)包括底座(171)、滑轨(172),底座(171)呈U型,滑轨(172)在底座(171)上平行间隔安装有两条,滑动支架(15)的底部对应设有两道滑槽,滑槽与滑轨(172)对应配合使滑动支架(15)底部与滑轨(172)滑动连接,传动丝杠(16)水平间隔设置于滑轨(172)上方,其一端与底座(171)的一侧面连接。
  5. 根据权利要求1所述的一种载人球形耐压壳焊接工作台,其特征在于:滑动支架(15)包括第一支座(151)、第二支座(152)、加强筋(153),第二支座(152)竖直固定于第一支座(151)上,第二支座(152)一侧面与第一支座(151)之间至少设有一个加强筋(153),工装轮(14)竖直放置安装于第二支座(152)的另一侧面上,第一支座(151)的底部与导轨台(17)滑动连接,传动丝杠(16)穿设于第二支座(152) 中。
  6. 根据权利要求1所述的一种载人球形耐压壳焊接工作台,其特征在于:工装轮(14)为镂空的圆柱形结构,两个工装轮(14)同轴对称。
  7. 一种权利要求1~6任一所述的载人球形耐压壳焊接工作台的加工方法,其特征在于包括以下步骤:
    第一步:前期加工在半球壳的球面留出凸台;
    将压制好的左右两个半球壳进行机加工,在两者的赤道位置分别加工出一道凸台;
    第二步:将工装内模嵌套在半球壳上进行定位;
    将两个半球壳分别嵌设于一个焊接工装组件上,使他们形成楔形结构,此时半球壳圆心与焊接工装组件圆心重合;
    第三步:采用点焊将两个半球壳与对应的焊接工装组件进行固定;
    第四步:将两个焊接工装组件分别安装在对应的工装轮上;
    第五步:进行焊接;
    将左右两个半球壳对接,通过传动丝杠带动工装支架沿着导轨台移动,将两个焊接工装组件相互定位,沿着焊缝进行焊接直至整个球体焊接到位;
    第六步:焊接完成后,待球体完全冷却下来,将两个焊接工装组件从导轨台上取下;
    第七步:取下工装内模;
    使用焊枪加热球面凸台与焊接工装组件焊点固定处,将焊接工装组件取下;
    第八步:切除球面凸台余量;
    对焊接好的整球进行机加工,将球面凸台加工切除,最后得到整球,加工完成。
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