A sheet metal deformation flame straightening device and a straightening method thereof

Abstract

The present application relates to a kind of sheet deformation flame straightening device and its straightening method, including pipe frame, and several welding nozzles are installed in the same pipe frame bottom in array distribution, the outside of welding nozzle is covered with flame tube, mixed gas pipe is arranged in pipe frame, and each welding nozzle is connected with the same mixed gas pipe, the side of welding nozzle is equipped with ignition needle arranged in flame tube, ignition plate corresponding with ignition needle is arranged below ignition needle and fixed on the inner wall of flame tube, and ignition needle is connected with high-frequency igniter through ignition pipeline.The present application uses array distribution welding nozzle to directly spray flame to heat and correct sheet, its flame beam diameter is small, and flame concentration is high, which guarantees correction quality and improves correction efficiency.

Description

Technical Field

[0001] This invention belongs to the field of thin plate correction technology, specifically relating to a thin plate deformation flame leveling device and its leveling method. Background Technology

[0002] In the rail transit industry and other sheet metal industries, there are many box-type or door-panel products whose structure generally consists of a steel frame and a thin sheet covering it (often called a skin). The manufacturing process typically involves connecting the two using fusion welding or resistance welding. Because welding these products along rectangular or circular trajectories on the thin sheet causes instability, wavy deformation occurs in the unused area on the skin where it doesn't contact the frame (or ribs) after welding. This deformation is difficult to correct using conventional leveling methods, such as hydraulic presses, jacks, or hammers. Furthermore, hydraulic presses are not practical for non-open structures like box-type structures, resulting in low-quality leveling and hindering production efficiency. Traditional flame straightening uses a single flame for point-by-point heating, which not only results in poor heating uniformity and inadequate leveling effect but also low leveling efficiency. Summary of the Invention

[0003] The purpose of this invention is to provide a thin plate deformation flame leveling device and its leveling method to solve the problems of poor quality and low efficiency in thin plate correction.

[0004] The thin plate deformation flame leveling device and its leveling method of the present invention are implemented as follows: A thin plate deformation flame leveling device includes a tube frame and several welding nozzles arranged in an array at the bottom of the same tube frame. Each welding nozzle is covered with a flame-gathering tube. A mixing gas tube is arranged inside the tube frame, and each welding nozzle is connected to the same mixing gas tube. An ignition needle is installed on one side of each welding nozzle and disposed inside the flame-gathering tube. An ignition plate is fixed on the inner wall of the flame-gathering tube and corresponds to the ignition needle below the ignition needle. The ignition needle is connected to a high-frequency igniter through an ignition pipeline.

[0005] Furthermore, the fire-gathering tube has through holes evenly distributed on its wall.

[0006] Furthermore, the bottom height of the fire-gathering tube is lower than the end height of the welding nozzle.

[0007] Furthermore, both the pipe rack and the mixing pipe have a serpentine structure, and at least one end of the pipe rack is provided with an air inlet seat connected to the end of the mixing pipe.

[0008] Furthermore, the air intake seat is provided with two air intake pipes, and each air intake pipe is provided with an air intake valve.

[0009] Furthermore, the ignition line is located on one side of each row of ignition tubes, and two adjacent rows of ignition needles are connected to the same high-frequency igniter.

[0010] Furthermore, the ignition circuit includes a conduit and several signal lines disposed within the conduit. One end of each signal line is connected to an ignition needle, and the other end is connected to a high-frequency igniter.

[0011] Furthermore, the tube rack is covered by a heat insulation frame, and the tube rack is installed inside the heat insulation frame by a clamping plate.

[0012] Furthermore, fixing plates are installed at the four corners of the outer wall of the heat insulation frame, and adjusting screws in the same direction as the welding nozzle are installed on the fixing plates.

[0013] Secondly, the present invention also provides a leveling method for a thin plate deformation flame leveling device, comprising the following steps: S01: Place the leveling device on the thin plate, that is, point its welding nozzle toward the thin plate to be leveled; S02: Adjust the distance between the welding nozzle and the thin plate to be leveled; S03: Introduce combustible gas and combustion-supporting gas into the mixing pipe; S04: Turn on the ignition switch on the high-frequency igniter to generate an ignition action between each ignition needle and its corresponding ignition plate; S05: The combustible gas inside the welding nozzle is ignited by the ignition action, forming a jet flame; S06: Adjust the flow rate and ratio of the combustion-supporting gas and / or combustible gas as needed to regulate the flame state.

[0014] After adopting the above technical solution, the beneficial effects of the present invention are as follows: (1) The present invention uses array-distributed welding nozzles to directly spray flames to heat and correct various parts of the thin plate that need to be corrected at the same time. The flame beam has a small diameter and high flame concentration. The heat is quickly heated through the thickness of the thin plate within a small diameter range on the surface of the thin plate. Under the principle of thermal expansion and contraction, the thin plate is immediately flattened to achieve the leveling effect. The heat transfer efficiency is high, which ensures the correction quality and improves the correction efficiency. (2) The flame state of each welding nozzle of the present invention is uniformly controlled, which can realize centralized and rapid adjustment of the flame, making it more convenient to use, with a large correction area, and further improving the correction efficiency. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0016] Figure 1 This is a structural diagram of the thin plate deformation flame leveling device according to a preferred embodiment of the present invention; Figure 2 This is a structural diagram of the thin plate deformation flame leveling device according to a preferred embodiment of the present invention; Figure 3 yes Figure 2 Enlarged view of section A; Figure 4 This is a bottom view of the thin plate deformation flame leveling device according to a preferred embodiment of the present invention; Figure 5 yes Figure 4 Cross-sectional view along the BB direction; Figure 6 yes Figure 4 Cross-sectional view along the CC direction; Figure 7 yes Figure 4 Cross-sectional view along the DD direction; In the diagram: 1. Pipe rack; 2. Welding nozzle; 3. Concentrating flame pipe; 4. Mixing gas pipe; 5. Ignition needle; 6. Ignition plate; 7. Ignition pipeline; 8. High-frequency igniter; 9. Fixing step sleeve; 10. Through hole; 11. Inlet seat; 12. Inlet pipe; 13. Inlet valve; 14. Through hole; 15. Heat insulation frame; 16. Clamping plate; 17. Vertical plate; 18. Clamping groove; 19. Fixing plate; 20. Adjusting screw; 21. Ignition switch. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0018] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0019] like Figure 1-7 As shown, a thin plate deformation flame leveling device includes a tube frame 1 and several welding nozzles 2 arranged in an array at the bottom of the same tube frame 1. The welding nozzles 2 are covered with a flame-gathering tube 3. A mixing gas tube 4 is arranged inside the tube frame 1, and each welding nozzle 2 is connected to the same mixing gas tube 4. An ignition needle 5 is installed on one side of the welding nozzle 2 and is disposed inside the flame-gathering tube 3. An ignition plate 6 is fixed on the inner wall of the flame-gathering tube 3 and corresponds to the ignition needle 5 below the ignition needle 5. The ignition needle 5 is connected to a high-frequency igniter 8 through an ignition pipe 7.

[0020] Specifically, a fixed step sleeve 9 is installed on the pipe rack 1, and the welding nozzle 2 is installed on the fixed step sleeve 9 by thread, and the welding nozzle 2 is connected to the mixing gas pipe 4 through the inner hole of the fixed step sleeve 9.

[0021] Preferably, welding nozzle 2 is a plum blossom shaped welding nozzle, which is less prone to backfire and has higher safety.

[0022] The flame concentrator 3 is designed to prevent the flame from spreading out over a large area or being blown away by the side wind, thereby increasing the concentration of the flame. In order to avoid the danger of excessively high gas concentration during ignition, the flame concentrator 3 is provided with through holes 10 evenly distributed on its wall.

[0023] Preferably, the flame concentrator 3 and the welding nozzle 2 are coaxially arranged, which can ensure the uniformity of the flame spreading or concentrating around the welding nozzle 2, thereby ensuring the calibration quality.

[0024] A neutral flame is a flame in which the oxygen supply during combustion is exactly equal to the oxygen required for the complete combustion of the combustible gas, and the afterburners contain neither excess oxygen nor reducing gases such as carbon monoxide generated due to oxygen deficiency. A neutral flame consists of three parts: the flame core, the inner flame, and the outer flame. The inner flame has the highest temperature, which depends on the ratio of oxygen to combustible gas and can reach up to 3300℃.

[0025] To ensure that the correction process utilizes the high-efficiency area of ​​the inner flame as much as possible, the distance between the welding nozzle 2 and the workpiece surface needs to be adjusted to a suitable height. Generally, when using a flame to perform point heating correction on thin plates, a neutral flame's inner flame is used, and the plate surface is heated as much as possible from the highest temperature flame area to improve preparation efficiency and heating concentration. Therefore, the bottom height of the flame concentrator 3 is lower than the end height of the welding nozzle 2.

[0026] When the leveling device is placed directly on the thin plate to be corrected, the flame concentrator 3 can be in direct contact with the thin plate, and the thin plate can be located in the inner flame of the flame, thereby improving the utilization rate of the flame.

[0027] Preferably, the height difference between the bottom of the fire-collecting tube 3 and the bottom of the welding nozzle 2 is 2-4mm.

[0028] The function of the pipe rack 1 is to install each welding nozzle 2 and facilitate the arrangement of the mixing gas pipe 4. In order to supply gas to each welding nozzle 2, both the pipe rack 1 and the mixing gas pipe 4 are serpentine structures, and at least one end of the pipe rack 1 is provided with an air inlet seat 11 connected to the end of the mixing gas pipe 4.

[0029] The mixing gas pipe 4 has the same shape as the pipe rack 1, both adopting a serpentine structure. The mixing gas pipe 4 is directly arranged inside the pipe rack 1, which makes it easy to connect each welding nozzle 2 to the same mixing gas pipe 4, thereby achieving unified adjustment of the flame state of each welding nozzle 2.

[0030] Preferably, the air inlet seat 11 is an isobaric air inlet seat, which operates on the same principle as an isobaric torch. The combustible gas and the combustion-supporting gas are mixed within the air inlet seat 11 without changing their own pressure, and then fed into the mixing pipe 4. This reduces the possibility of backfire during the heating and calibration process, improving safety. Correspondingly, the welding nozzle 2 uses a propane-specific plum blossom-shaped welding nozzle.

[0031] Optionally, the air inlet seat 11 can also be a jet-type air inlet seat, which has an internal jet-type structure and operates on the same principle as a jet-type cutting torch. In this case, an acetylene welding nozzle should be selected to work with the jet-type air inlet seat.

[0032] In addition, in this embodiment, two air inlets 11 are provided, which are installed at both ends of the pipe rack 1 and connected to both ends of the mixing pipe 4. One air inlet 11 can be used to supply air to the mixing pipe 4 while the other air inlet 11 is closed. Alternatively, both air inlets 11 can be used to supply air to the mixing pipe 4 at the same time, which results in higher air supply efficiency.

[0033] The structure of the tube rack 1 and the mixing gas pipe 4 is not limited to the serpentine shape used in this embodiment. It can also be U-shaped, circular or spiral, etc., so that the welding nozzles 2 on the tube rack 1 are distributed in an array and each welding nozzle 2 is connected to the same mixing gas pipe 4.

[0034] Specifically, the tube frame 1 can be a square tube or a round tube. In this embodiment, the tube frame 1 is a round tube structure.

[0035] To facilitate the introduction of combustible gas and combustion-supporting gas into the mixing pipe 4, two air inlet pipes 12 are provided on the air inlet seat 11, and each air inlet pipe 12 is provided with an air inlet valve 13.

[0036] Oxygen is introduced into one of the mixing pipes 4 as the combustion-supporting gas, and propane or acetylene is introduced into the other mixing pipe 4 as the combustible gas, with propane being the preferred combustible gas.

[0037] When using an equal pressure inlet seat, combustible gas and combustion-supporting gas enter the inlet seat 11 at a certain pressure. After mixing, they directly enter the mixing pipe 4 to supply gas to each welding nozzle 2.

[0038] In order to achieve rapid ignition of each welding nozzle 2, the ignition line 7 is set on one side of each row of fire collection tubes 3, and the two adjacent rows of ignition needles 5 are connected to the same high-frequency igniter 8.

[0039] Each high-frequency igniter 8 ignites each welding nozzle 2 connected to it sequentially. In this embodiment, there are eight rows of welding nozzles 2. Every two rows are ignited by the same high-frequency igniter 8. The four high-frequency igniters 8 can be turned on simultaneously or sequentially, which can improve the ignition efficiency accordingly.

[0040] The high-frequency igniter 8 is not limited to being connected to two rows of ignition needles 5 as used in this embodiment. It can also be connected to one or more rows of ignition needles 5, or the ignition needles 5 on the same leveling device can be controlled by only the same high-frequency igniter 8.

[0041] In order for the high-frequency lighter 8 to control the ignition action of the ignition needle 5, the ignition circuit 7 includes a conduit and several signal lines installed in the conduit. One end of the signal line is connected to the ignition needle 5 in a one-to-one correspondence, and the other end is connected to the high-frequency lighter 8.

[0042] Specifically, in this embodiment, the ignition pipeline 7 and the pipe rack 1 are serpentine structures of the same shape and are placed in the same direction as the pipe rack, while the high-frequency igniter 8 is set at one end of the two rows of ignition needles 5 connected to it.

[0043] Several signal wires of the high-frequency igniter 8 pass through the conduit and are connected to the corresponding ignition needles 5, thereby controlling the ignition action of the ignition needles 5.

[0044] Preferably, the ignition needle 5 is an alumina ceramic ignition needle.

[0045] The conduit provides excellent protection for the signal lines. It can be made of alumina ceramic material and has a heat insulation layer on its inner wall. The heat insulation layer is preferably made of nanoporous heat insulation material, which has excellent heat insulation effect and prevents damage to the signal lines.

[0046] Specifically, both sides of the ignition tube 3 are provided with through holes 14. The ignition line 7 extends into the ignition tube 3 through one of the through holes 14 and extends downward. The ignition needle 5 is installed at the end of the ignition line 7, and the ignition plate 6 is located directly below the ignition needle 5.

[0047] Preferably, the surface of the ignition plate 6 is treated with rust prevention to extend the service life of the ignition plate 6.

[0048] The high-frequency igniter 8 can be selected from, but is not limited to, multi-output ignition devices produced by Xianyang Xiran Electric Automation Engineering Co., Ltd.

[0049] In order to achieve heat insulation for the leveling device, the tube rack 1 is covered with a heat insulation frame 15, and the tube rack 1 is installed inside the heat insulation frame 15 by a clamping plate 16.

[0050] Preferably, heat insulation cotton is installed on the inner wall of the heat insulation frame 15.

[0051] Specifically, the outer perimeter of the heat insulation frame 15 is a frame structure, the top of which is hollowed out and has a vertical plate 17. A horizontal slot 18 is installed inside the slot 18, which is corresponding to the plate 16. The two have arc-shaped grooves. The pipe rack 1 is placed in the arc-shaped groove on the slot 18 and fixed by the plate 16 and screws.

[0052] The tube rack 1 is not limited to the above-mentioned method of fixing the card plate 16 and the card slot 18; other structures that can fix it are also acceptable.

[0053] The heat insulation frame 15 can be square or round.

[0054] In this embodiment, the air intake seat 11 is located on the outside of the heat insulation frame 15 on the side where the end of the tube frame 1 is located, while the high-frequency igniter 8 is located on the opposite side of the air intake seat 11, also located outside the heat insulation frame 15.

[0055] Since the flame sprayed by the welding nozzle 2 is conical, the farther the welding nozzle 2 is from the thin plate, the larger its correction range will be when the correction range needs to be adjusted. In order to facilitate the adjustment of the distance between the welding nozzle 2 and the thin plate, fixing plates 19 are installed in a four-corner distribution on the outer wall of the heat insulation frame 15. Adjusting screws 20 in the same direction as the welding nozzle 2 are installed on the fixing plates 19.

[0056] Specifically, the fixing plate 19 is symmetrically installed on both sides adjacent to the side where the air intake seat 11 is located. When it is necessary to adjust the distance between the welding nozzle 2 and the thin plate, it can be achieved by adjusting the rotation of the screw 20 on the fixing plate 19.

[0057] In addition, the setting of the adjusting screw 20 can provide the leveling device with sufficient adjustment space during the flame state adjustment process to prevent backfire. It can also adjust the flame height by adjusting the adjusting screw 20 on the basis of the basic height, so as to select the shortest distance as much as possible without backfire, in order to maximize the utilization of thermal efficiency and ensure the concentration of flame.

[0058] Secondly, this embodiment also provides a leveling method for a thin plate deformation flame leveling device, including the following steps: Since the shapes and areas of the thin plates that need to be corrected are different, the shape and specifications of the leveling device can be selected in advance according to the specifications of the thin plates that need to be corrected.

[0059] In this embodiment, the pipe rack 1 adopts a serpentine structure, while the welding nozzle 2 adopts a 6×8 array distribution.

[0060] The thin plate deformation flame leveling device is not limited to the structure provided in this embodiment. The pipe rack can also be a U-shaped structure, a circular structure, or a spiral structure. Furthermore, depending on the shape and specifications of the thin plate, different sizes of welding nozzles 2 can be selected, as well as array structures with different spacing, all of which can effectively heat the thin plate. Additionally, multiple leveling devices can be assembled together for thin plate correction; simply connecting adjacent leveling devices with hooks is sufficient.

[0061] S01: Place the leveling device on the thin plate, that is, point its welding nozzle 2 toward the thin plate to be leveled; During calibration, the flame emitted by the welding nozzle 2 comes into direct contact with the thin plate, thereby improving the heating effect and ensuring the calibration effect and efficiency.

[0062] S02: Adjust the distance between welding nozzle 2 and the thin plate to be leveled; If it is necessary to increase the calibration range of the leveling device, the adjusting screw 20 is rotated toward the thin plate to increase the distance between the leveling device and the thin plate, thereby adjusting the size range of the flame heating point of the leveling device.

[0063] S03: Introduce combustible gas and combustion-supporting gas into the mixing pipe 4; Before ignition, combustible gas and combustion aid need to be introduced. Open the corresponding air inlet valve 13 and let it enter the mixing pipe 4 through the air inlet seat 11 to supply gas to each welding nozzle 2.

[0064] S04: Turn on the ignition switch 21 on the high-frequency igniter 8 to generate an ignition action between each ignition needle 5 and its corresponding ignition plate 6. In this embodiment, four high-frequency igniters 8 are provided. After the gas is supplied, the ignition switches 21 on the four high-frequency igniters 8 are turned on sequentially or simultaneously. The high-frequency igniters 8 transmit voltage signals to the ignition needles 5 through the signal lines corresponding to each ignition needle 5. The ignition needles 5 release voltage, forming a voltage drop between themselves and the ignition plate 6, producing a spark, and successfully igniting the combustible gas in the welding nozzle 2, thereby realizing the sequential ignition of each welding nozzle 2 connected to the same high-frequency igniter 8.

[0065] S05: The combustible gas inside the welding nozzle 2 is ignited by the ignition action, forming a jet flame; S06: Adjust the flow rate and ratio of the combustion-supporting gas and / or combustible gas as needed to regulate the flame state.

[0066] Since using a neutral flame inner flame can reduce energy consumption, reduce pollution and improve heat utilization, it is necessary to adjust the flame state according to the distance between the welding nozzle 2 and the thin plate and through the air inlet valve so that the thin plate is in the inner flame part of the flame, thus ensuring the correction efficiency and correction effect.

[0067] This invention employs an array of welding nozzles 2 to directly flame-heat and correct the thin plate to be corrected, thereby increasing the uniformity of heating and the heat transfer effect, and improving the quality and efficiency of correction. Furthermore, the flames generated by the various welding nozzles 2 on the leveling device can be uniformly adjusted, simplifying the operation steps and making it more convenient to use.

[0068] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A thin plate deformation flame leveling device, characterized in that, The device includes a pipe rack (1) and several welding nozzles (2) arranged in an array at the bottom of the same pipe rack (1). The welding nozzles (2) are covered with a fire-gathering tube (3). A mixing gas tube (4) is arranged inside the pipe rack (1), and each welding nozzle (2) is connected to the same mixing gas tube (4). An ignition needle (5) is installed on one side of the welding nozzle (2) and is located inside the fire-gathering tube (3). An ignition plate (6) is fixed on the inner wall of the fire-gathering tube (3) and corresponds to the ignition needle (5) below the ignition needle (5). The ignition needle (5) is connected to a high-frequency igniter (8) through an ignition pipe (7). The bottom height of the fire-gathering tube (3) is lower than the end height of the welding nozzle (2); The fire-gathering tube (3) has through holes (10) evenly arranged on its tube wall; Both the pipe rack (1) and the mixing pipe (4) are serpentine structures, and at least one end of the pipe rack (1) is provided with an air inlet seat (11) connected to the end of the mixing pipe (4); The ignition line (7) is set on one side of each column of ignition tubes (3), and two adjacent columns of ignition needles (5) are connected to the same high-frequency igniter (8). The fire-gathering tube (3) and the welding nozzle (2) are coaxially arranged; When the leveling device is placed directly on the thin plate to be corrected, the fire-collecting tube (3) is placed in direct contact with the thin plate.

2. The thin plate deformation flame leveling device according to claim 1, characterized in that, The air intake seat (11) is provided with two air intake pipes (12), and each air intake pipe (12) is provided with an air intake valve (13).

3. The thin plate deformation flame leveling device according to claim 1, characterized in that, The ignition circuit (7) includes a conduit and several signal lines installed inside the conduit. One end of each signal line is connected to an ignition needle (5) and the other end is connected to a high-frequency igniter (8).

4. The thin plate deformation flame leveling device according to claim 1, characterized in that, The tube rack (1) is covered by a heat insulation frame (15), and the tube rack (1) is installed inside the heat insulation frame (15) by a clamp (16).

5. The thin plate deformation flame leveling device according to claim 4, characterized in that, Fixing plates are installed at four corners on the outer wall of the heat insulation frame (15), and adjusting screws (20) in the same direction as the welding nozzle (2) are installed on the fixing plates.

6. A leveling method for a thin plate deformation flame leveling device, characterized in that, Includes the following steps: S01: Place the leveling device on the thin plate, that is, point its welding nozzle (2) toward the thin plate to be leveled; The leveling device includes a pipe rack (1) and several welding nozzles (2) arranged in an array at the bottom of the same pipe rack (1). The welding nozzles (2) are covered with fire-gathering tubes (3). The fire-gathering tubes (3) have through holes (10) evenly arranged on their walls. The bottom height of the fire-gathering tubes (3) is lower than the end height of the welding nozzles (2). When the leveling device is placed directly on the thin plate to be corrected, the fire-collecting tube (3) is in direct contact with the thin plate; S02: Adjust the distance between the welding nozzle (2) and the thin plate to be leveled; S03: Introduce combustible gas and combustion-supporting gas into the mixing pipe (4); At least one end of the pipe rack (1) is provided with an air inlet seat (11) connected to the end of the gas mixing pipe (4). The air inlet seat (11) is provided with two air inlet pipes (12), and each air inlet pipe (12) is provided with an air inlet valve (13). S04: Turn on the ignition switch (21) on the high-frequency igniter (8) to make each ignition needle (5) and its corresponding ignition plate (6) generate an ignition action; S05: The combustible gas inside the welding nozzle (2) is ignited by the ignition action to form a jet flame; S06: Adjust the flow rate and ratio of the combustion-supporting gas and / or combustible gas as needed to regulate the flame state.

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