A spiral welding machine splicing and welding device and process for the production of PCCP steel cylinders

Abstract

This application relates to the field of PCCP steel cylinder manufacturing, and particularly to a spiral welding machine plate welding device and process for PCCP steel cylinder manufacturing; it includes a flipping mechanism, a spiral welding machine, and a welding platform; the flipping mechanism that can support and flip the coil plate to be attached to the core of the spiral welding machine is located on one side of the core of the spiral welding machine. In this application, the coil plate is placed on the electromagnet support table, and the position of the coil plate is fixed and corrected through the adsorption function of the electromagnet support table; through the rotation function of the flipping table, the coil plate is flipped to a set angle; then the coil plate is transported and completely attached to the core through the transportation platform; finally, straight seam welding and circumferential seam welding are carried out through an automatic welding machine; this application realizes the plate welding process of the steel cylinder on the spiral welding machine equipment, solves the problem of spiral cracks on the inner wall of the PCCP finished pipe; at the same time, compared with the traditional plate welding process, it reduces the labor input and improves the quality control of the size and appearance of the steel cylinder in the plate welding process.

Description

Technical Field

[0001] This application relates to the field of PCCP steel cylinder manufacturing, and particularly to a spiral welding machine plate welding device, process and products obtained therefrom for PCCP steel cylinder manufacturing. Background Art

[0002] Prestressed concrete cylinder pipe (abbreviated as PCCP in English) refers to a pipe made by winding circumferential prestressed steel wires on the outer side of a concrete pipe core with a steel cylinder and making a cement mortar protective layer. It is generally used for urban water supply and drainage main pipes, industrial water pipelines, farmland irrigation, factory pipe networks, power plant make-up water pipes and cooling water circulation systems, inverted siphons, pressure tunnel pipelines, pipe trenches, pipe galleries and deep-covered culverts, etc.

[0003] When manufacturing PCCP, it is divided into: socket and spigot manufacturing, steel cylinder manufacturing, pipe core concrete manufacturing, winding circumferential prestressed steel wires, and roller spraying cement mortar protective layer. Currently, when manufacturing steel cylinders in China, the spiral welding process is adopted. After the steel cylinder is manufactured, through pipe core concrete manufacturing, winding circumferential prestressed steel wires, and roller spraying cement mortar protective layer, the finished pipe is finally formed. However, spiral cracks are found on the inner wall surface of the finished pipe. Through analysis and research, it is found that the shape of the cracks is basically the same as that of the spiral weld of the steel cylinder, and it can be inferred that the spiral cracks are related to the spiral welding process of the steel cylinder.

[0004] According to the national standard for PCCP product manufacturing, "Prestressed Concrete Cylinder Pipe" GB / T 19685, the steel cylinder body can be manufactured by spiral welding or plate welding, and the final dimensions of the steel cylinder body should meet the design requirements. Currently, the spiral welding process is adopted in the domestic PCCP industry to manufacture steel cylinders, but spiral cracks are extremely likely to appear on the inner wall of the finished pipe. Although the national standard allows the appearance of spiral cracks, if the concrete strength is not well controlled and the height of the steel cylinder weld is not well controlled, the width of the inner spiral weld of the finished pipe will exceed 0.5 mm, leaving potential quality hazards for the products.

[0005] By analyzing the causes of the spiral cracks and according to the location and law of the appearance of the spiral cracks, it is found that the cracks all appear at the spiral welds of the steel cylinder. Therefore, it can be determined that the generation of the spiral cracks on the inner wall of the PCCP pipe is related to the stress release of the spiral welds on the spiral welded steel cylinder. Summary of the Invention

[0006] The purpose of this application is to propose a spiral welding machine plate welding device, process and products for PCCP steel cylinder manufacturing that can eliminate spiral cracks and quality hazards.

[0007] One of the technical solutions of this application is implemented as follows: A spiral welding machine splicing and welding device for manufacturing PCCP steel cylinders, which includes a flipping mechanism, a spiral welding machine, and a welding platform; The flipping mechanism that can support and flip the coiled plate to be attached to the core of the spiral welding machine is located on one side of the core of the spiral welding machine. There is a welding track on the welding platform with a setting direction consistent with the axis direction of the core of the spiral welding machine, and an automatic welding machine is installed through the welding track. The welding platform is located on the other side of the core, and the welding point of the automatic welding machine is correspondingly located at the outer wall position of the core.

[0008] Further, the flipping mechanism includes a conveying track, a conveying platform, a flipping table, and an electromagnet support table; The setting direction of the conveying track is horizontal and perpendicular to the axis direction of the core of the spiral welding machine; The electromagnet support table with a concave arc-shaped upper end face is fixedly installed in the flipping table. One end of the flipping table close to the core of the spiral welding machine is connected with a hinge shaft and is rotatably installed on the conveying platform through the hinge shaft. The conveying platform is slidably installed in the conveying track.

[0009] Further, it also includes a transport chain bracket, a coiling machine, and an arc bracket; The output end of the transport chain bracket for transporting flat plates corresponds to the inlet end of the coiling machine, and the outlet end of the coiling machine corresponds to the upper bearing end face of the arc bracket.

[0010] Further, two or four automatic welding machines are installed in the welding track; Or / and, raised positioning rings are respectively provided at both ends of the core of the spiral welding machine.

[0011] Another technical solution of this application is implemented as follows: A spiral welding machine splicing and welding process for manufacturing PCCP steel cylinders, which includes the following steps:

[0012] Step 1, fix the socket steel ring and the spigot steel ring at both ends of the core respectively, and rotate the core to the starting position;

[0013] Step 2, place the coiled plate on the electromagnet support table, turn on the adsorption function of the electromagnet support table to fix and correct the position of the coiled plate; Start the rotation function of the flipping table to flip the coiled plate to a set angle; Then move the coiled plate to one side of the core along the conveying track through the conveying platform until the coiled plate is completely attached to the core and is located between the socket steel ring and the spigot steel ring;

[0014] Step 3, manually fix the coiled plate on the socket steel ring and the spigot steel ring with CO2 shielded welding spot welding, cancel the adsorption function of the electromagnet support table, and reset the electromagnet support table, the flipping table, and the conveying platform;

[0015] Step 4, repeat Step 2 and Step 3, and attach the second coiled plate in the same way. The coiled plates are overlapped in sequence, and the overlapping part is manually spot welded with CO2 shielded welding;

[0016] Step 5, fix all the coiled plates on the core;

[0017] Step 6: Adjust the rotation angle of the spiral welding machine, start the automatic welding machine after aligning it with the weld seam, and the automatic welding machine performs straight seam welding along the welding track.

[0018] Step 7: Adjust the position of the automatic welding machine to align the welding point of the automatic welding machine with the welding positions of the steel cylinder spliced by the coiled plates and the socket steel ring, and the welding position of the steel cylinder and the spigot steel ring; the core rotates, and the automatic welding machine performs circumferential seam welding.

[0019] Furthermore, in Step 4, the overlapping width of the coiled plates does not exceed 10 mm.

[0020] Furthermore, in Step 6, a cut coiled plate for adjustment is not overlapped at the first and the last positions.

[0021] The third technical solution of this application is implemented as follows: The product obtained by the spiral welding machine plate welding process for PCCP steel cylinder production includes wide coiled plates and narrow coiled plates; a complete cylinder is composed of multiple wide coiled plates and one narrow coiled plate; straight weld seams parallel to the axis of the cylinder are connected between the wide coiled plates and between the wide coiled plates and the narrow coiled plates; a cross bridge covering the straight weld seam is provided on the inner wall of the cylinder corresponding to each straight weld seam; between every two adjacent cross bridges, transverse ribs parallel to the axis of the cylinder are further provided on the inner wall of the cylinder.

[0022] Furthermore, the overlapping width between the wide coiled plates is not more than 10 mm, and the overlapping width between the wide coiled plates and the narrow coiled plates is not more than 10 mm; the overlapping directions of the multiple wide coiled plates and one narrow coiled plate forming the cylinder are the same; the cross bridge is a copper cross bridge.

[0023] Furthermore, a rotatable core is provided inside the cylinder in a matching manner; positioning blocks are respectively provided at both ends of the core, and a socket steel ring and a spigot steel ring are fixed on the core through the positioning blocks, and the socket steel ring and the spigot steel ring are respectively connected to both ends of the cylinder through circumferential weld seams.

[0024] Due to the implementation of the above technical solution, in this application, the coiled plates are placed on the electromagnet support table, and the position of the coiled plates is fixed and corrected through the adsorption function of the electromagnet support table; through the rotation function of the turning platform, the coiled plates are rotated to a set angle; then the coiled plates are transported and completely attached to the core through the transport platform; finally, straight seam welding and circumferential seam welding are performed through the automatic welding machine; this application realizes the plate welding process of the steel cylinder on the spiral welding machine equipment, solves the problem of spiral cracks on the inner wall of the PCCP finished pipe; at the same time, compared with the traditional plate welding process, it reduces the labor input and improves the quality control of the steel cylinder size and appearance in the plate welding process. Description of the Drawings

[0025] The specific structure of this application is given by the following drawings and embodiments:

[0026] Figure 1 It is a schematic structural diagram of Embodiment 1 of this application.

[0027] Figure 2 It is a schematic structural diagram of Embodiment 3 of the present application.

[0028] Legend: 1. Wide coiled plate, 2. Straight weld seam, 3. Cross bridge, 4. Cross rib, 5. Core of the cylinder, 6. Positioning block, 7. Socket steel ring, 8. Spigot steel ring, 9. Circumferential weld seam, 10. Spiral welding machine, 11. Welding platform, 12. Welding track, 13. Automatic welding machine, 14. Conveyor track, 15. Conveyor platform, 16. Turning table, 17. Magnet support table, 18. Conveyor chain bracket, 19. Plate rolling machine, 20. Arc bracket, 21. Flat bracket, 22. Cut-to-size plate. Detailed implementation manners

[0029] The present application is not limited by the following embodiments, and specific implementation manners can be determined according to the technical solutions of the present application and actual situations.

[0030] Embodiment 1, as Figure 1 shown, a spiral welding machine plate welding device for manufacturing a PCCP steel cylinder includes a turning mechanism, a spiral welding machine 10 and a welding platform 11; the turning mechanism capable of supporting and turning a coiled plate to be attached to the core 5 of the spiral welding machine 10 is located on one side of the core 5 of the spiral welding machine 10, a welding track 12 with a setting direction consistent with the axis direction of the core 5 of the spiral welding machine 10 is provided on the welding platform 11, and an automatic welding machine 13 is installed through the welding track 12. The welding platform 11 is located on the other side of the core 5 and the welding point of the automatic welding machine 13 is correspondingly located at the outer wall position of the core 5.

[0031] During operation, place the coiled plate on the turning mechanism, turn the coiled plate to a set angle through the turning mechanism, transport and completely attach it to the core 5; finally, perform straight seam welding and circumferential seam welding through the automatic welding machine 13; the present application realizes the plate welding process of the steel cylinder on the spiral welding machine 10 equipment, solves the problem of spiral cracks on the inner wall of the PCCP finished pipe; at the same time, compared with the traditional plate welding process, it reduces the labor input and improves the quality control of the steel cylinder size and appearance in the plate welding process.

[0032] The automatic welding machine 13 can adopt two dedicated welding machines for CO2 shielded welding and be installed with a weld seam tracker.

[0033] As an optimization of Embodiment 1, as Figure 1 shown, the turning mechanism includes a conveyor track 14, a conveyor platform 15, a turning table 16, and an electromagnet support table 17; the setting direction of the conveyor track 14 is horizontal and perpendicular to the axis direction of the core 5 of the spiral welding machine 10; the electromagnet support table 17 with a concave arc-shaped upper end face is fixedly installed in the turning table 16. One end of the turning table 16 close to the core 5 of the spiral welding machine 10 is connected with a hinge shaft and is rotatably installed on the conveyor platform 15 through the hinge shaft, and the conveyor platform 15 is slidably installed in the conveyor track 14.

[0034] As an optimization of Embodiment 1, as Figure 1 shown, it further includes a transport chain bracket 18, a plate rolling machine 19, and an arc bracket 20; the output end of the transport chain bracket 18 for transporting flat plates corresponds to the inlet end of the plate rolling machine 19, and the outlet end of the plate rolling machine 19 corresponds to the upper bearing surface of the arc bracket 20.

[0035] During installation, the original open-screen plate loading cart of the spiral welding machine 10 needs to be removed, and the plate rolling machine 19 can be installed at this position, which can be a three-roll plate rolling machine 19; a flat bracket 21 can also be arranged in front of the transport chain bracket 18; use a 10T forklift to transport the 6T - 7T open flat plate 22 to the flat bracket 21, adjust the plate rolling machine 19 to the required rolling radian, manually place a single open flat plate 22 on the transport chain bracket in front of the plate rolling machine 19, and make the single open flat plate 22 enter the plate rolling machine 19 through the transport chain. The rolled plate automatically falls onto the arc bracket 20 behind the plate rolling machine 19. Finally, manually move the rolled plate to the electromagnet support table 17.

[0036] As an optimization of Embodiment 1, as Figure 1 shown, two or four automatic welding machines 13 are installed in the welding track 12; and / or, positioning rings are respectively provided at both ends of the core 5 of the spiral welding machine 10.

[0037] Embodiment 2, as Figure 1 、 2 shown, a spiral welding machine splicing and welding process for PCCP steel cylinder manufacturing includes the following steps: Step 1, fix the socket steel ring 7 and the spigot steel ring 8 at both ends of the core 5 respectively, and rotate the core 5 to the starting position; Step 2, place the rolled plate on the electromagnet support table 17, turn on the adsorption function of the electromagnet support table 17 to fix and correct the position of the rolled plate; start the rotation function of the flipping table 16 to flip the rolled plate to the set angle; then move the rolled plate to one side of the core 5 along the transport platform 15 along the transport track 14 until the rolled plate completely adheres to the core 5 and is located between the socket steel ring 7 and the spigot steel ring 8; Step 3, manually fix the rolled plate on the socket steel ring 7 and the spigot steel ring 8 by CO2 spot welding, cancel the adsorption function of the electromagnet support table 17, and the electromagnet support table 17, the flipping table 16, and the transport platform 15 return to their original positions; Step 4, repeat Step 2 and Step 3, and adhere the second rolled plate in the same way. The rolled plates are overlapped in sequence, and the overlapping part is manually spot-welded by CO2; Step 5, fix all the rolled plates on the core 5; Step 6, adjust the rotation angle of the spiral welding machine 10, start the automatic welding machine 13 after aligning it with the weld seam, and the automatic welding machine 13 performs straight seam welding along the welding track 12; Step 7, adjust the position of the automatic welding machine 13 to make the welding point of the automatic welding machine 13 align with the welding positions of the steel cylinder spliced by the rolled plates and the socket steel ring 7, and the welding position of the steel cylinder and the spigot steel ring 8; rotate the core 5, and the automatic welding machine 13 performs circumferential seam welding.

[0038] In Step 6, during straight seam welding, the straight seam can be welded after all the coiled plates are fixed on the core 5, or welding can start after the first straight seam rotates to the welding position. However, the circumferential seam in Step 7 must be welded after all the straight seams are welded to reduce the welding stress on the steel cylinder body.

[0039] As an optimization of Example 2, as Figure 1 shown, in Step 4, the lapping width of the coiled plate does not exceed 10 mm.

[0040] As an optimization of Example 2, in Step 6, a cut coiled plate for adjustment is not lapped at the first and the last positions.

[0041] Before the present application was adopted, according to the statistics of PCCP product data produced by the spiral welded steel cylinder process in 2020, among 150 sections of PCCP pipes, 130 sections had spiral cracks on the inner wall, and the occurrence rate of spiral cracks was as high as 87%. After 320 sections of PCCP pipes were produced by the process of the present application, no spiral cracks were found on the inner wall, and the occurrence rate of spiral cracks was zero.

[0042] Based on the above data, it can be obtained that the spiral welding machine splicing and welding process for PCCP steel cylinder production solves the problem of spiral cracks on the inner wall of PCCP pipes, and the quality of its products has been greatly improved.

[0043] Taking the production of a DN3600mm steel cylinder as an example, about 15 workers are required for the traditional splicing and welding process; after adopting the spiral welding machine splicing and welding process for PCCP steel cylinder production, only about 5 workers are required, and the labor input is saved by more than 65% compared with the traditional process.

[0044] After adopting the spiral welding machine splicing and welding process for PCCP steel cylinder production, the roundness, appearance and dimensional quality of the obtained steel cylinder are significantly improved compared with those of the steel cylinder produced by the traditional splicing and welding process.

[0045] Example 3, as Figure 2 shown, the product obtained by the spiral welding machine splicing and welding process for PCCP steel cylinder production includes wide coiled plates 1 and narrow coiled plates; a complete cylinder is composed of multiple wide coiled plates 1 and one narrow coiled plate; straight welds 2 parallel to the axis of the cylinder are connected between wide coiled plates 1 and between wide coiled plates 1 and narrow coiled plates; a cross bridge 3 covering the straight weld 2 is provided on the inner wall of the cylinder corresponding to each straight weld 2; between every two adjacent cross bridges 3, transverse ribs 4 parallel to the axis of the cylinder are further provided on the inner wall of the cylinder.

[0046] Taking the production of a steel cylinder with a diameter of DN3600 as an example, the DN3600 steel cylinder needs to be spliced with 9 whole plates and a small plate with a width of about 720mm. Therefore, there are 10 longitudinal welds 2 and 2 circumferential welds 9 on the DN3600 steel cylinder, thus forming a cylindrical shape. It is necessary to install a cross-bridge 3 with a thickness of 20mm and a width of 80mm under the longitudinal weld 2 on the core 5. The function of the cross-bridge 3 is to ensure that the wide and narrow rolled plates are not welded to the core 5 when welding the longitudinal weld 2. A φ20 cross-reinforcement 4 needs to be installed at a certain interval between two cross-bridges 3 to ensure the roundness of the finally spliced steel cylinder.

[0047] The spliced steel cylinder has no problem of spiral cracks, and the quality is greatly improved; it solves the problem of spiral cracks on the inner wall of the PCCP finished pipe, and improves the roundness, shape accuracy and appearance quality of the steel cylinder.

[0048] Such as Figure 2 shown, the lap width between the wide rolled plates 1 and the wide rolled plates 1 is not more than 10mm, and the lap width between the wide rolled plate 1 and the narrow rolled plate is not more than 10mm.

[0049] Such as Figure 2 shown, the lap directions of the multiple wide rolled plates 1 and one narrow rolled plate forming the cylinder are the same; the cross-bridge 3 is a copper cross-bridge 3.

[0050] Such as Figure 2 shown, a rotatable core 5 is equipped inside the cylinder; positioning blocks 6 are respectively arranged at both ends of the core 5, and a socket steel ring 7 and a spigot steel ring 8 are fixed on the core 5 through the positioning blocks 6. The socket steel ring 7 and the spigot steel ring 8 are respectively connected to both ends of the cylinder through circumferential welds 9.

[0051] In this article, "up", "down", "front", "back", "left", "right", etc. are only used to represent the relative positional relationship between relevant parts, rather than limiting the absolute positions of these relevant parts.

[0052] The above technical features constitute the embodiments of the present application, which have strong adaptability and implementation effects. Non-essential technical features can be increased or decreased according to actual needs to meet the needs of different situations.

Claims

1. A spiral welding machine splicing and welding device for manufacturing PCCP steel cylinders, characterized in that: It includes a flipping mechanism, a spiral welding machine, and a welding platform; the flipping mechanism that can support and flip the coiled plate to be attached to the core of the spiral welding machine is located on one side of the core of the spiral welding machine. There is a welding track on the welding platform with a setting direction consistent with the axis direction of the core of the spiral welding machine, and an automatic welding machine is installed through the welding track. The welding platform is located on the other side of the core, and the welding point of the automatic welding machine corresponds to the position on the outer wall of the core; the flipping mechanism includes a conveying track, a conveying platform, a flipping table, and an electromagnet support platform; the setting direction of the conveying track is horizontal and perpendicular to the axis direction of the core of the spiral welding machine; the electromagnet support platform with a concave arc-shaped upper end surface is fixedly installed in the flipping table. One end of the flipping table close to the core of the spiral welding machine is connected with a hinge shaft and is rotatably installed on the conveying platform through the hinge shaft, and the conveying platform is slidably installed in the conveying track.

2. The spiral welding machine splicing and welding device for manufacturing PCCP steel cylinders according to claim 1, characterized in that: It further includes a transport chain bracket, a coiling machine, and an arc bracket; the output end of the transport chain bracket for transporting flat plates corresponds to the inlet end of the coiling machine, and the outlet end of the coiling machine corresponds to the upper bearing surface of the arc bracket.

3. The spiral welding machine splicing and welding device for manufacturing PCCP steel cylinders according to claim 2, characterized in that: Two or four automatic welding machines are installed in the welding track; and / or, positioning rings are respectively provided at both ends of the core of the spiral welding machine.

4. A spiral welding machine splicing and welding process for manufacturing PCCP steel cylinders, characterized in that using the spiral welding machine splicing and welding device for manufacturing PCCP steel cylinders as described in claim 2 or 3: including the following steps: Step 1, fix the socket steel ring and the spigot steel ring at both ends of the core respectively, and rotate the core to the starting position; Step 2, place the coiled plate on the electromagnet support platform, turn on the adsorption function of the electromagnet support platform, fix and correct the position of the coiled plate; start the rotation function of the flipping table, flip the coiled plate to the set angle; then move the coiled plate to one side of the core along the conveying platform along the conveying track until the coiled plate is completely attached to the core and is located between the socket steel ring and the spigot steel ring; Step 3, manually fix the coiled plate on the socket steel ring and the spigot steel ring by CO2 spot welding, cancel the adsorption function of the electromagnet support platform, and the electromagnet support platform, the flipping table, and the conveying platform return to their original positions; Step 4, repeat Step 2 and Step 3, attach the second coiled plate in the same way, and the coiled plates are overlapped in sequence, and the overlapping part is manually spot welded by CO2; Step 5, fix all the coiled plates on the core; Step 6, adjust the rotation angle of the spiral welding machine, align the running automatic welding machine with the weld seam and then start, and the automatic welding machine performs straight seam welding along the welding track; Step 7, adjust the position of the automatic welding machine to make the welding point of the automatic welding machine align with the welding positions of the steel cylinder spliced by the coiled plates and the socket steel ring, and the welding position of the steel cylinder and the spigot steel ring; the core rotates, and the automatic welding machine performs circumferential seam welding.

5. The spiral welding machine splicing and welding process for manufacturing PCCP steel cylinders according to claim 4, characterized in that: In step 4, the lapping width of the coiled plate does not exceed 10 mm.

6. The spiral welding machine splicing welding process for PCCP steel cylinder production according to claim 4 or 5, characterized in that: In step 6, a cut coiled plate for adjustment is not lapped at the first and the last pieces.

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