Coil manufacturing apparatus and method

Abstract

This invention relates to a coil manufacturing apparatus and method, belonging to the technical field of tube bending machines. The apparatus includes a frame with a crossbeam mounted on it. A pressure roller assembly is located at the bottom of the crossbeam, and a tube bending pusher is positioned between the crossbeam and the pressure roller assembly. The pressure roller assembly includes a driving pressure roller and driven pressure rollers, with at least two driven pressure rollers positioned below the driving pressure rollers. The driven pressure rollers are movable to adjust the gap between themselves and the driving pressure rollers, allowing the tube entering the gap to bend and wind around the crossbeam, gradually forming a coil upon contact with the tube bending pusher. This apparatus can adjust the distance between the driven and driving rollers according to the diameter of the coils in different boilers, ensuring the bent tube is wound around the crossbeam and that the outer wall of the bent tube contacts the tube bending pusher, thus enabling continuous coil processing.

Description

Technical Field

[0001] This invention belongs to the field of pipe bending machine technology, specifically relating to a coil manufacturing device and method. Background Technology

[0002] Boilers are essential heat energy supply equipment in the national economy, widely used in industries such as power, metallurgy, chemical, textile, and papermaking. The boiler body mainly consists of the boiler drum, headers, and coils. With the development of industrial equipment, the demand for heat energy is increasing, and boiler bodies are becoming larger. This requires larger dimensions and diameters for the coils or spiral tubes inside the boiler. Furthermore, to improve heat exchange efficiency, boiler coils are typically arranged in double or multiple tube configurations. Currently, conventional tube bending machines in China have complex structures, large overall dimensions, complicated operation, and a limited range of bending diameters. Moreover, different boilers usually have different coil diameters, making it difficult for current conventional tube bending machines to continuously process coils of varying diameters. Summary of the Invention

[0003] To address the technical problems existing in the prior art, the present invention provides a coil manufacturing apparatus and method. This apparatus can adjust the distance between the driven pressure roller and the driving pressure roller according to the diameter of the coil in different boilers, so that the bent tube is wound around the crossbeam, and the outer wall of the bent tube is in contact with the bending pusher, thus enabling continuous processing of the coil.

[0004] This invention provides a coil manufacturing apparatus, characterized in that it includes a frame, a crossbeam on the frame, a pressure roller component at the bottom of the crossbeam, and a tube bending pusher between the crossbeam and the pressure roller component. The pressure roller component includes an active pressure roller and a driven pressure roller, wherein there are at least two driven pressure rollers, which are disposed below the active pressure roller. The driven pressure rollers are movable to adjust the gap between themselves and the active pressure roller, so that the tube entering the gap bends and wraps around the crossbeam, and gradually forms a coil by contacting the tube bending pusher.

[0005] Furthermore, the frame includes a first support column and a second support column, the crossbeam is disposed between the first support column and the second support column, the bending tube pusher is mounted on the first support, and the pressure roller assembly is disposed on the side of the first support column facing the second support column.

[0006] Furthermore, brackets are installed on both the first and second support columns, and two spaced-apart roller bearings are provided on the brackets. The two ends of the crossbeam are placed between the two spaced-apart roller bearings.

[0007] Furthermore, the bracket is slidably mounted on the support column and can move up and down on the support column.

[0008] Furthermore, each of the top ends of the first and second support columns is provided with a linear drive component, which is connected to the end of the crossbeam to control the up and down movement of the crossbeam.

[0009] Furthermore, a support platform is provided at the bottom between the first support column and the second support column.

[0010] Furthermore, the active pressure roller is mounted on the first support column, and a drive component for controlling the rotation of the active pressure roller is provided on the first support column.

[0011] Furthermore, a guide wheel is provided on one side of the pressure roller component, through which the unbent pipe can be conveyed into the gap between the active pressure roller and the passive pressure roller.

[0012] Furthermore, the driven pressure roller is fixed to the ground by a telescopic drive component.

[0013] This invention also provides a manufacturing method for a coil manufacturing apparatus based on any one of the above-described embodiments, the method comprising the following steps:

[0014] Determine the height of the crossbeam and the gap between the active and driven pressure rollers based on the diameter of the coil and the bent tube.

[0015] The tube to be bent is placed between the active pressure roller and the driven pressure roller. The active pressure roller is rotated to transport the tube to be bent. At the same time, the distance between the driven pressure roller and the active pressure roller is continuously adjusted so that the tube begins to bend and wrap around the crossbeam. By contacting the tube bending pusher, the tube on the crossbeam is wound around the crossbeam in a spiral shape, gradually forming a coil.

[0016] The beneficial effects of this invention are as follows:

[0017] The coil manufacturing apparatus provided by this invention has a crossbeam on the frame to support the bent coil, ensuring the stability of the coil processing. By adjusting the distance between the driven pressure roller and the driving pressure roller, the bent tube can be wound around the crossbeam. At the same time, when the end of the bent tube comes into contact with the bending pusher, the bending pusher can be controlled to move horizontally, ensuring that the bent tube is wound around the crossbeam in a spiral shape, thus enabling continuous processing of the coil. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a coil manufacturing apparatus provided in an embodiment of the present invention;

[0019] Figure 2 This is a schematic diagram of the pressure roller component structure provided in an embodiment of the present invention.

[0020] In the diagram: 1. Operating platform, 2. Lifting cylinder, 3. First support column, 4. Hydraulic oil station, 5. Electrical control cabinet, 6. Rotary motor, 7. Cycloidal pinwheel reducer, 8. Coupling, 9. Bending pipe pusher, 10. Coil, 11. Crossbeam, 12. Chain hoist, 13. Bracket, 14. Second support column, 15. Driven pressure roller, 16. Driven pressure roller, 17. Guide wheel. Detailed Implementation

[0021] See Figure 1 As shown in the figure, an embodiment of the present invention provides a coil manufacturing apparatus, which includes a frame and a crossbeam 11 provided on the frame, the crossbeam 11 being able to move up and down on the frame.

[0022] A pressure roller assembly is provided at the bottom of the crossbeam 11 on the frame. The pressure roller assembly includes an active pressure roller 16 and a driven pressure roller 15. The active pressure roller 16 is located at the bottom of the crossbeam 11, and there are at least two driven pressure rollers 15 located below the active pressure roller 16.

[0023] The driven pressure roller 15 can be moved up and down to adjust the gap between itself and the driving pressure roller 16. When the tube to be bent enters between the driving pressure roller 16 and the driven pressure roller 15, the gap between the driven pressure roller 15 and the driving pressure roller 16 can be adjusted to make the tube bend and simultaneously wind it onto the crossbeam 11 to begin the coiling process.

[0024] As the tube is wound, it needs to be continuously pushed to one side to achieve the processing of coiled or spiral tubes. In this embodiment, a tube bending pusher 9 is provided between the crossbeam 11 and the pressure roller component. The tube bending pusher 9 can move horizontally. When the end of the tube wound on the crossbeam initially comes into contact with the tube bending pusher 9, the tube bending pusher 9 is controlled to move horizontally to give the tube a horizontal force. In this way, as the tube is continuously bent and wound, the outer wall of the tube wound on the crossbeam is always in contact with the tube bending pusher 9. Thus, the bent tube will be wound on the crossbeam in a spiral shape.

[0025] Therefore, the bending device provided in this embodiment of the invention has a crossbeam on the frame, which can be used to support the bent coil and ensure the stability of the coil processing. By adjusting the distance between the driven pressure roller and the active pressure roller, the bent tube can be wound around the crossbeam. At the same time, when the end of the bent tube comes into contact with the bending pusher, the bending pusher can be controlled to move horizontally, ensuring that the bent tube is wound around the crossbeam in a spiral shape. This enables continuous processing of the coil.

[0026] Specifically, see Figure 1As shown, the frame in this embodiment includes a first support column 3 and a second support column 14, wherein the first support column 3 and the second support column 14 are both placed vertically, and the crossbeam 11 is installed between the first support column 3 and the second support column 14.

[0027] Chain hoists 12 are installed on the top of the first support column 3 and the second support column 14. The chain hoists 12 are connected to both ends of the crossbeam 11. By controlling the chain hoists 12, the crossbeam 11 can be moved up and down.

[0028] To ensure the stability of the horizontal beam 11 during vertical movement, the first support column 3 and the second support column 14 can be provided with sliding grooves. The two ends of the horizontal beam 11 are installed in the sliding grooves by pulleys, which is beneficial to the stability of the horizontal beam 11 during vertical movement.

[0029] Of course, the up-and-down movement of the crossbeam 11 is not limited to the chain hoist 12 in this embodiment. Other transmission mechanisms can also be used, such as hydraulic cylinder drive. The bottom of the hydraulic cylinder rod is installed on the top of the support column, and the end of the hydraulic cylinder telescopic rod is directly connected to the crossbeam 11, which can also drive the crossbeam 11 to move up and down.

[0030] After the pipe is completely bent and fitted onto the crossbeam 11 to form the coil 10, the bent coil 10 needs to be removed from the crossbeam 11. For easy removal of the coil, please refer to [link / reference needed]. Figure 1 As shown, in this embodiment, both the first support column 3 and the second support column 14 are provided with brackets 13. The brackets 13 are slidably installed on the support columns, and the installation method is the same as the installation method of the crossbeam 11 described above. The chain hoist 12 is directly connected to the brackets 13.

[0031] The two ends of the crossbeam 11 are placed directly on the brackets 13 on the first support column 3 and the second support column 14. After all the pipes on the crossbeam 11 are bent, the two ends of the crossbeam 11 can be fixed by the hoisting tool. Then the crossbeam 11 and the coils on the crossbeam 11 are lifted up from the frame and placed in an empty space. Then the crossbeam 11 can be pulled out from one side of the coils.

[0032] The shape of the bracket 13 in this example is not limited. Two bearings, such as tapered rollers, are provided at the top of the bracket 13. The gap between the two bearings is smaller than the diameter of the crossbeam 11. The crossbeam 11 can be placed between the two bearings to reduce the coefficient of rotational friction of the crossbeam 11 when supporting the coil.

[0033] Preferably, the crossbeam 11 in this embodiment is tubular in shape, so that the crossbeam 11 can roll between two spaced bearings on the bracket 13.

[0034] Further, see Figure 1 and Figure 2As shown, the pressure roller assembly in this example includes an active pressure roller 16 and a driven pressure roller 15, with the active pressure roller 16 on top and the driven pressure roller 15 on the bottom. The tube to be bent passes through the gap between the active pressure roller 16 and the driven pressure roller 15 and is bent to wrap around the crossbeam 11.

[0035] There are two driven pressure rollers 15, which are respectively arranged on both sides of the active pressure roller 16. The driven pressure rollers 15 can move up and down. They can not only adjust the gap between the active pressure roller 16 and the driven pressure roller 15 according to the diameter of the pipe to be bent, but also adjust the bending radius of the pipe to be bent through the driven pressure roller 15 on the right.

[0036] To achieve the vertical movement of the driven pressure roller 15, see [link to relevant documentation]. Figure 1 As shown, in this embodiment, the bottom of the driven pressure roller 15 is controlled by the lifting cylinder 2 to control its lifting function. The top of the lifting cylinder 2 can be directly fixed on the ground and is connected to the driven pressure roller 15.

[0037] It should be noted that the number of driven pressure rollers 15 in this embodiment is not limited to two, but can also be more than two, each moving independently. This facilitates the bending of the tube. The first driven pressure roller located at the tube inlet primarily ensures that the tube can enter between the driven and driven pressure rollers, while the remaining driven pressure rollers mainly bend the tube. The more driven pressure rollers there are, the more accurate the bending radius can be.

[0038] See Figure 1 As shown, in this embodiment, the bending pipe pusher 9 is installed on the first support column. In order to realize the horizontal movement of the bending pipe pusher 9, the bending pipe pusher can be fixed on the first support column by a horizontal drive component, such as a horizontal hydraulic cylinder, so that a horizontal force can be applied to the coil.

[0039] The shape of the bending pusher is not limited, and the part that contacts the bending tube can be made into an arc surface with a smooth surface. It is preferably made of plastic material to avoid the bending pusher from contacting the outer wall of the tube, thereby damaging the outer wall of the coil.

[0040] In this embodiment, an operating platform 1 is also provided at the bottom of the crossbeam 11. The operator can stand on the operating platform 1 to measure or observe the bending of the coiled pipe.

[0041] See Figure 2 As shown, in this embodiment, a guide wheel 17 is also provided on one side of the pressure roller component. The tube to be bent can be placed on the guide wheel 17, and the tube to be bent can be transported between the active pressure roller 16 and the driven pressure roller 15 through the guide wheel 17.

[0042] Preferably, the guide wheel 17 can also move up and down. Its specific connection structure can be the same as that of the active pressure roller 16 and the driven pressure roller 15, and can be directly fixed on the bottom surface. Further details will not be provided here.

[0043] See Figure 1 As shown, in this embodiment, a rotary motor 6 is provided on the first support column 3. The rotary motor 6 is connected to the active pressure roller 16 through a cycloidal pinwheel reducer 7 and a coupling 8, so that the active pressure roller 16 can be rotated.

[0044] The device also includes an electrical control cabinet 5, which is connected to the rotary motor 6 and the hydraulic oil station 4 respectively. The hydraulic oil station 4 is connected to the lifting cylinder 2. Thus, the drive of the rotary motor 6 and the lifting cylinder 2 can be controlled through the electrical control cabinet 5.

[0045] The following describes in detail a method for manufacturing a coil manufacturing apparatus based on the above embodiments, the method comprising the following steps:

[0046] Step 1: Determine the height of the crossbeam 11 and the gap between the driven pressure roller 15 and the driving pressure roller 16 according to the required diameter of the bent coil and the pipe.

[0047] Step 2: Place the pipe to be bent on the guide wheel 17, and control the rotation of the guide wheel 17 to transport the pipe to be bent between the active pressure roller 16 and the driven pressure roller 15.

[0048] Step 3: Start the active pressure roller 16 to continue conveying the tube to be bent, and at the same time control the driven pressure roller 15 on the right to move upward, so that the tube begins to bend and wrap around the crossbeam 11. When the end of the tube wrapped around the crossbeam first comes into contact with the tube bending pusher 9, control the tube bending pusher 9 to move horizontally to give the tube a horizontal force. At the same time, as the coil continues to wrap, the tube wrapped around the crossbeam will be wrapped around the crossbeam in a spiral posture.

[0049] Step 4: After all the coils on the crossbeam 11 are wound, suspend both sides of the crossbeam 11 with slings, then move the crossbeam 11 and the coils on the crossbeam 11 to an empty area in the workshop, and remove the crossbeam 11 inside the coils to complete the coiling work.

[0050] The manufacturing method provided in the above example is easy to operate and can adjust the height of the crossbeam and the gap between the active pressure roller 16 and the driven pressure roller 15 according to the diameter of the coil in different boilers to achieve continuous processing of coils or spiral tubes.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

[0052] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A coil manufacturing apparatus characterized by comprising: The device includes a frame with a crossbeam on it. A pressure roller assembly is located at the bottom of the crossbeam. A bending tube pusher that can move horizontally is located between the crossbeam and the pressure roller assembly. The pressure roller assembly includes an active pressure roller and a driven pressure roller, wherein there are at least two driven pressure rollers, which are located below the active pressure roller. The driven pressure roller can move up and down to adjust the gap between itself and the active pressure roller according to the diameter of the tube to be bent. The bending radius of the tube to be bent is adjusted by the driven pressure roller on the right side, so that the tube entering the gap bends and wraps around the crossbeam and gradually forms a coil upon contact with the bending tube pusher. Each of the driven pressure rollers moves independently. The first driven pressure roller located at the pipe inlet ensures that the pipe can enter between the driven pressure roller and the driving pressure roller, while the other driven pressure rollers bend the pipe. The frame includes a first support column and a second support column. The crossbeam is disposed between the first support column and the second support column. A bracket is installed on both the first support column and the second support column. The bracket is provided with two spaced-apart roller bearings. The two ends of the crossbeam are placed between the two spaced-apart roller bearings. The gap between the two bearings is smaller than the diameter of the crossbeam. The bending tube pusher is mounted on the first support column, and the pressure roller component is located on the side of the first support column facing the second support column; The bracket is slidably mounted on the support column and can move up and down on the support column; Linear drive components are provided at the top of both ends of the first and second support columns; The bending pusher is made of plastic material; a support platform is provided at the bottom between the first support column and the second support column; The manufacturing method of the coil manufacturing apparatus includes the following process: Determine the height of the crossbeam and the gap between the active and driven pressure rollers based on the diameter of the coil and the bent tube. The tube to be bent is placed between the active pressure roller and the driven pressure roller. The active pressure roller is rotated to transport the tube to be bent. At the same time, the distance between the driven pressure roller and the active pressure roller is continuously adjusted so that the tube begins to bend and wrap around the crossbeam. By contacting the tube bending pusher, the tube on the crossbeam is wound around the crossbeam in a spiral shape, gradually forming a coil. The two ends of the crossbeam are placed directly on the brackets on the first and second support columns. After all the pipes on the crossbeam are bent, the two ends of the crossbeam can be fixed with a hoisting tool. Then, the crossbeam and the coils on the crossbeam are lifted up from the frame and placed in an empty space. Then, the crossbeam can be pulled out from one side of the coils.

2. An apparatus for manufacturing a coil as defined in claim 1, wherein The active pressure roller is mounted on the first support column, and a drive component for controlling the rotation of the active pressure roller is provided on the first support column.

3. The coil manufacturing apparatus of claim 1 wherein, A guide wheel is provided on one side of the pressure roller component, which can transport the unbent pipe into the gap between the active pressure roller and the passive pressure roller.

4. The coil manufacturing apparatus of claim 1 wherein, The driven pressure roller is fixed to the ground by a telescopic drive component.

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