Large gear tooth surface on-site quenching equipment

Abstract

This invention relates to an on-site quenching device for the surface of large gear teeth, comprising a traveling base; an integrated flame-heated and water-cooled nozzle mounted on the traveling base, with upper and lower supports separated at their front ends to form a tooth machining position; both the upper and lower supports are equipped with a flame jet section and a water spray section, with the flame nozzle of the flame jet section and the water spray holes of the water spray section facing the tooth machining position; a welding torch having an input end connected to an oxygen storage tank and an acetylene storage tank, and a mixer output end connected to the flame jet section; and a water inlet pipe connected to the water spray section. This invention employs flame heating on each tooth surface and simultaneous cooling with cooling water, achieving the desired heat treatment for the gear working surface, and is suitable for on-site, non-disassembly quenching of the tooth surface of large gears.

Description

Technical Field

[0001] This invention belongs to the field of machining machinery technology, and relates to a large gear machining device, and more particularly to a large gear tooth surface quenching equipment. Background Technology

[0002] Large gears are used in ball mills. Due to the harsh working environment and the heavy workload of their transmission, the open-type gears bear heavy loads for extended periods, resulting in severe wear on their working surfaces. After the original hardened layer wears away, on-site strengthening treatment is required to extend the service life of the large gears. However, the large gears in ball mills are integrated with the cylinder, making them extremely heavy and bulky, and integrally feeding them into the furnace is clearly not feasible. Currently, there is a lack of processing equipment that allows for on-site surface hardening heat treatment without disassembling the ball mill equipment. Summary of the Invention

[0003] The purpose of this application is to address the above-mentioned problems by providing a field quenching device for the surface of large gear teeth;

[0004] This invention creatively proposes a large gear tooth surface in-situ quenching equipment, comprising:

[0005] Walking base;

[0006] The integrated flame-heated and water-cooled nozzle is mounted on a walking base and has an upper support and a lower support that are separated at the front end to form a tooth machining position. Both the upper support and the lower support are equipped with a flame jet section and a water spray section. The flame nozzle of the flame jet section and the water spray hole of the water spray section are both facing the tooth machining position.

[0007] The welding torch has an input end that connects to an oxygen storage tank and an acetylene storage tank, and a mixer output end that connects to the flame jet.

[0008] Water inlet pipe, connected to the water spray unit.

[0009] By heating the surface of each tooth while simultaneously cooling it with cooling water, quenching can be performed in a feasible, simple, and effective manner, achieving the purpose of heat treatment on the working surface of the gear in online conditions, thus meeting mechanical performance requirements and extending service life.

[0010] The walking base is connected to a linear drive with a speed adjustment device. A temperature sensor is installed on the walking base. The temperature sensor is connected to the speed adjustment device of the linear drive via a temperature controller. When the temperature of the temperature sensor is higher than the set range of the temperature controller, the linear drive is controlled to accelerate. When the temperature of the temperature sensor is lower than the set range of the temperature controller, the linear drive is controlled to decelerate.

[0011] Temperature sensors ensure that the flame precisely heats each tooth surface to the quenching temperature.

[0012] A circulating cooling water pipe is provided on the side of the flame jet section. The inlet end of the circulating cooling water pipe is connected to the water inlet pipe, and the outlet end is connected to the water outlet pipe.

[0013] The circulating cooling water pipe is used to cool the flame jet section, ensuring that it does not malfunction due to overheating of the nozzle.

[0014] The inlet and outlet pipes are connected to a water tank to form a water circulation system.

[0015] The flame jets on the upper and lower supports are each U-shaped, the circulating cooling water pipe is located outside the flame jet, and the water spray section is located outside the circulating cooling water pipe.

[0016] The water spray section includes a first water spray branch pipe and a second water spray branch pipe respectively arranged on both sides of the flame spray section. The first water spray branch pipe, the second water spray branch pipe and the water inlet pipe are connected by a two-position three-way reversing valve. The traveling base drives the flame heating and water cooling integrated nozzle to move laterally back and forth.

[0017] A water receiving tray is installed below the first and second water spray branch pipes. The bottom of the water receiving tray is connected to the water tank through a return water pipe to realize the circulation of spray water and meet the requirements of energy conservation, environmental protection and clean production.

[0018] It can switch its working state according to the travel path through two spray branch pipes with the same water inlet but different water return, so as to ensure precise cooling and temperature control in both directions of operation.

[0019] The flame nozzles are several arranged in staggered rows. Each row of flame nozzles is arranged along the front and back of the flame jet section, and the flame portions of adjacent flame nozzles in each row overlap or connect.

[0020] Two rows of flame nozzles are arranged in a staggered manner, with the flames overlapping or connected to cover the surface of the large gear, thus meeting the need for continuous and uniform heating of the tooth-shaped quenched surface.

[0021] The spacing between adjacent flame nozzles in each row gradually increases from front to back.

[0022] The spacing between adjacent flame nozzles gradually increases from front to back, allowing the flame to evenly cover the surface of the involute curved gear, thus ensuring uniform heating of the gear surface.

[0023] The outlet of the flame nozzle has a transitional conical channel that gradually increases in size from the inside to the outside.

[0024] This improves the problem of poor airflow, prevents the heater from catching fire due to small air outlets, and avoids the occurrence of "explosion" and blockage.

[0025] The upper and lower supports are hinged at their rear ends, and the upper and lower supports are fixed together by adjusting nuts and set screws to adjust the included angle between the upper and lower supports.

[0026] The upper and lower supports are adjustable, making this device suitable for machining tooth profiles of different sizes.

[0027] The oxygen storage tank is connected to multiple oxygen cylinders via an oxygen manifold, and the acetylene storage tank is connected to multiple acetylene cylinders via an acetylene manifold.

[0028] It can achieve alternating gas supply and cylinder replacement to ensure stable gas storage outlet pressure.

[0029] Compared with the prior art, the advantages of this application are:

[0030] 1) This invention uses flame heating on each tooth surface and simultaneous cooling with cooling water to achieve the purpose of heat treatment on the working surface of the gear. It is suitable for tooth surface quenching of large gears on-site without disassembly. It has a simple structure, low cost, and can meet mechanical performance requirements and extend service life.

[0031] 2) The integrated flame-heated and water-cooled nozzle works in conjunction with the walking base to control the temperature of the heated surface and the cooling rate during the walking process, enabling bidirectional processing, improving the hardness of the tooth surface, and reducing processing costs. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of a large gear tooth surface on-site quenching equipment provided in this application.

[0033] Figure 2 This is a partial structural diagram in a side view provided in this application.

[0034] Figure 3 This is a partial structural diagram from a top view provided in this application.

[0035] Figure 4 This is a partial structural diagram from a bottom-view perspective provided in this application.

[0036] Figure 5 This is a side view structural diagram of a flame jet section provided in this application.

[0037] Figure 6 This is a schematic diagram of the forward-looking structure of a flame jet section provided in this application.

[0038] Figure 7 This is a structural schematic diagram of an integrated quick-connect gas-water distribution plate provided in this application.

[0039] Figure 8 This is a schematic diagram of the internal structure of an integrated quick-connect gas-water distribution plate provided in this application.

[0040] Figure 9 This is a schematic diagram of the structure of a spray water distribution pipe provided in this application.

[0041] Figure 10 This is a schematic diagram of the structure of a cooling circulating water distribution pipe provided in this application.

[0042] Figure 11 This is a schematic diagram of the structure of a gas distribution pipe provided in this application.

[0043] Figure 12 This is a schematic block diagram of the circuit structure provided in this application.

[0044] In the diagram: 1. Walking base; 11. Support; 12. Linear track; 13. Linear actuator; 2. Integrated flame heating and water cooling nozzle; 21. Upper support; 22. Lower support; 23. Flame jet section; 231. Flame nozzle; 232. Transition conical channel; 24. Water spray section; 241. First water spray branch pipe; 242. Second water spray branch pipe; 243. Water spray hole; 25. Adjusting nut; 26. Set screw; 27. Circulating cooling water pipe; 3. Welding torch; 31. Oxygen storage tank; 32. Oxygen manifold. 311, Oxygen Cylinder 312, Acetylene Storage Tank 32, Acetylene Manifold 321, Acetylene Cylinder 322, Mixer Output Terminal 33, Inlet Pipe 4, Water Pump 41, Water Tank 42, Outlet Pipe 43, Water Drawer 44, Return Pipe 45, Control Valve 46, Temperature Sensor 5, Temperature Controller 6, Two-Position Three-Way Reversing Valve 8, Throttling Valve 81, Integrated Quick-Connect Gas-Water Distribution Plate 9, Spray Water Distribution Pipe 91, Cooling Circulating Water Distribution Pipe 92, Gas Distribution Pipe 93. Detailed Implementation

[0045] The following specific examples further illustrate this point;

[0046] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the invention is not limited to the specific embodiments disclosed below.

[0047] like Figure 1 As shown, a large gear tooth surface on-site quenching equipment includes a moving system, a flame-heated and water-cooled integrated nozzle 2, a heating system, and a water inlet system.

[0048] The mobile system can use the walking speed adjustment control device of a semi-automatic gas cutter to provide power for walking along the width of the tooth surface, such as the CG3-100 semi-automatic gas cutter.

[0049] Specifically, the mobile system includes a walking base 1, a support 11, and a linear actuator 13. The support 11 has outriggers that extend and retract in the vertical direction. A linear track is provided on the support 11. The walking base 1 cooperates with the linear track 12 and is driven to move by the linear actuator 13.

[0050] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the flame-heated and water-cooled integrated nozzle 2 is mounted on the walking base 1, and the width direction of the flame-heated and water-cooled integrated nozzle 2 is parallel to the straight track.

[0051] The flame-heated and water-cooled integrated nozzle 2 has an upper support 21 and a lower support 22 with their front ends separated to form a toothed machining position.

[0052] The lower bracket 22 is connected to the integrated quick-connect gas-water distribution plate 9, and the upper bracket 21 is hinged to the lower bracket 22 via a hinge.

[0053] Furthermore, the rear ends of the upper bracket 21 and the lower bracket 22 are hinged and can be opened and rotated along the vertical plane. An adjusting nut 25 is provided on the upper bracket 21 along the vertical direction. A set screw 26 is threaded into the adjusting nut 25. The bottom end of the set screw 26 is pressed into the groove on the upper surface of the lower bracket 22. The angle between the upper bracket 21 and the lower bracket 22 is adjusted by fixing the adjusting nut 25 and the set screw 26.

[0054] Both the upper support 21 and the lower support 22 are equipped with a flame jet section 23, a water spray section 24, and a circulating cooling water pipe 27.

[0055] The flame jet section 23, water spray section 24, and circulating cooling water pipe 27 of the upper bracket 21 and lower bracket 22 are connected to the integrated quick-connect air-water distribution plate 9 via high-temperature resistant hoses or copper pipes. The high-temperature resistant hoses provide greater adjustable angles, while the copper pipes provide higher stability.

[0056] Both the upper support 21 and the lower support 22 have U-shaped flame jet sections 23, with both ends connected to the heating system. Each flame jet section 23 has several flame nozzles 231 spaced apart. The circulating cooling water pipes 27 are also U-shaped, closely attached to the outside of the flame jet sections 23. One end of each circulating cooling water pipe 27 is connected to the inlet pipe 4, and the other end is connected to the outlet pipe 43. The water spray section 24 consists of two branch pipes, respectively located on both sides of the circulating cooling water pipes 27. These two branch pipes are connected to the inlet pipe 4 via a two-position three-way directional valve 8 and a throttle valve.

[0057] like Figure 4 , Figure 5 and Figure 6As shown, the flame nozzles 231 comprise several, arranged in two rows along the U-shaped pipe in a front-to-back direction. The spacing between adjacent flame nozzles 231 in each row increases in steps from front to back. The initial spacing is set according to the tooth gap size, nozzle shape, and heating time, and increases with the tangent of the line connecting the tooth root and tooth tip. The flames of adjacent flame nozzles 231 in each row overlap or connect. The flames of the two rows of flame nozzles 231 partially overlap or connect on the orthographic projection plane, thereby ensuring uniform heating coverage.

[0058] The outlet of the flame nozzle 231 has a transitional conical channel 232 that gradually increases from the inside to the outside. The diameter of the flame nozzle 231 is 40.5 mil. The transitional conical channel 232 can prevent the heater from misfiring, "banging" and clogging at this diameter.

[0059] like Figure 4 As shown, the water spray section 24 includes a first water spray branch pipe 241 and a second water spray branch pipe 242 respectively disposed on both sides of the flame spray section 23. The first water spray branch pipe 241 and the second water spray branch pipe 242 are parallel to the two sides of the U-shaped pipe. A plurality of water spray holes 243 are respectively provided on the first water spray branch pipe 241 and the second water spray branch pipe 242 at intervals.

[0060] Several water spray holes 243 are arranged in a row parallel to the flame nozzle 231.

[0061] like Figure 1 , Figure 2 and Figure 4 As shown, the first water spray branch pipe 241, the second water spray branch pipe 242 and the water inlet pipe 4 are connected by a two-position three-way reversing valve 8, and the traveling base 1 drives the flame heating and water cooling integrated nozzle 2 to move laterally back and forth.

[0062] The traveling base 1 moves along the linear track 12 under the drive of the linear actuator 13. The linear actuator 13 can be a cylinder, hydraulic cylinder, or motor, and has a speed adjustment device. The linear actuator 13 with the speed adjustment device is a structure found in commercially available products and is known to those skilled in the art, so it will not be described in detail here. The linear actuator 13 controls the traveling base 1 to reciprocate along the width direction of the flame-heated water-cooled integrated nozzle 2 within a specific range.

[0063] A temperature sensor 5 is installed above the integrated quick-connect air-water distribution plate 9. The temperature sensor 5 can be an infrared temperature sensor. The sensing end of the temperature sensor 5 faces the tooth machining position. The temperature sensor 5 is connected to the temperature controller 6.

[0064] like Figure 12As shown, the temperature sensor 5 is connected to the speed adjustment device of the linear actuator 13 via the temperature controller 6. In the initial state, the linear actuator 13 drives the walking base 1 to move at a constant speed v0. When the temperature is higher than the set range of the temperature controller 6, the linear actuator 13 drives the walking base 1 to move at a speed v1 greater than v0. When the temperature is lower than the set range of the temperature controller 6, the linear actuator 13 drives the walking base 1 to move at a speed v2 less than v0.

[0065] In one embodiment, the two-position three-way directional valve 8 is a manual valve.

[0066] In one embodiment, the two-position three-way directional valve 8 is an electric valve. The two-position three-way directional valve 8 is connected to the linear actuator 13 via photoelectric sensors or proximity sensors located at both ends of the stroke of the linear actuator 13. When the linear actuator 13 drives the walking base 1 to the displacement limit on the side of the first water spray branch pipe 241, the two-position three-way directional valve 8 connects the first water spray branch pipe 241 with the water inlet pipe 4. When the linear actuator 13 drives the walking base 1 to the displacement limit on the side of the second water spray branch pipe 242, the two-position three-way directional valve 8 connects the second water spray branch pipe 242 with the water inlet pipe 4.

[0067] like Figure 1 , Figure 2 and Figure 4 As shown, the flame nozzle 231 of the flame jet section 23 and the water spray hole 243 of the water spray section 24 both face the tooth machining position. That is, the flame nozzle 231 and water spray hole 243 on the upper bracket 21 are provided on the lower surface of the upper bracket 21, and the flame nozzle 231 and water spray hole 243 on the lower bracket 22 are provided on the upper surface of the lower bracket 22.

[0068] The heating system includes a welding torch 3, which has an input end connected to an oxygen storage tank 31 and an acetylene storage tank 32, and a mixer output end 33 connected to a flame jet unit 23.

[0069] In this embodiment, welding torch 3 is an H01-20 welding torch.

[0070] Oxygen storage tank 31 is connected to multiple oxygen cylinders 312 via oxygen manifold 311, and each oxygen cylinder 312 is equipped with an individual switch valve. Acetylene storage tank 32 is connected to multiple acetylene cylinders 322 via acetylene manifold 321, and each acetylene cylinder 322 is equipped with an individual switch valve.

[0071] Gas is supplied and cylinders are changed in rotation to ensure that the outlet pressure of the oxygen storage tank is stable at 1-1.1 MPa and the outlet pressure of the acetylene storage tank 32 is stable at 0.1-0.13 MPa.

[0072] like Figure 1 and Figure 2As shown, the mixer output end 33 of the welding torch 3 is connected to the walking base 1 through an integrated quick-connect gas-water distribution plate 9.

[0073] like Figure 1 and Figure 2 As shown, the water inlet system includes an inlet pipe 4, a water tank 42, an outlet pipe 43, a water receiving tray 44, and a return pipe 45.

[0074] The inlet pipe 4 is connected to the water spray section 24 and the circulating cooling water pipe 27. The inlet pipe 4 is connected to the water tank 42 via the water pump 41. The water pump 41 and the throttle valve 81 work together to regulate the water pressure, maintaining it between 0.12 and 0.2 MPa to ensure water stability and thus the stability of quenching hardness. The inlet pipe 4 and the outlet pipe 43 form a water circulation system by connecting to the water tank 42.

[0075] The water receiving tray 44 is located at the front end of the walking base 1 and below the first water spray branch pipe 241 and the second water spray branch pipe 242. The bottom of the water receiving tray 44 is connected to the water tank 42 through the return water pipe 45 to realize the circulation of spray water.

[0076] like Figure 7 , Figure 8 , Figure 9 , Figure 10 and Figure 11 As shown, the integrated quick-connect air-water distribution plate 9 specifically includes two sets of spray water distribution pipes 91, two sets of cooling circulating water distribution pipes 92, and two sets of air distribution pipes 93.

[0077] Combination Figure 1 , Figure 7 , Figure 8 and Figure 9 The inlets of the two sets of spray water distribution pipes 91 are connected to the water inlet pipe 4 through a two-position three-way reversing valve 8 and a throttle valve 81, and the outlets are connected to the first water spray branch pipe 24 of the upper and lower supports and the second water spray branch pipe 242 of the upper and lower supports, respectively.

[0078] Combination Figure 3 , Figure 8 and Figure 10 One set of cooling water distribution pipes 92 has its inlet connected to the inlet pipe 4 via a control valve 46, and its outlet connected to one end of the circulating cooling water pipe 27 of the upper and lower supports. The other set of cooling water distribution pipes 92 has its inlet connected to the outlet pipe 43, and its outlet connected to the other end of the circulating cooling water pipe 27 of the upper and lower supports.

[0079] like Figure 2 , Figure 8 and Figure 11 As shown, the inlets of both sets of gas distribution pipes 93 are connected to the welding torch 3, and the outlets are connected to the two ends of the flame jet section 23 of the upper and lower supports, respectively.

[0080] The integrated quick-connect gas-water distribution plate 9 enables rapid connection of various pipelines, effectively avoiding pipeline connection chaos and saving space and installation time.

[0081] The working principle of this invention is as follows:

[0082] The temperature controller 6 is pre-set with the highest and lowest critical temperatures. The integrated flame-heated and water-cooled nozzle 2 is moved to the position of the gear tooth to be processed, with the upper support 21 and lower support 22 positioned on the upper and lower sides of the tooth to be processed, respectively. The welding torch 3 is started for heating, and the control valve 46 of the circulating cooling water pipe 27 is started for circulating water cooling. The traveling base 1 moves from one end of the tooth to the other end along the tooth width direction. The water spray section 24 on the side of the flame jet section 23 away from the traveling direction is started for water spraying and quenching. When reversing, the two-position three-way reversing valve 8 is reversed, and the water spray section 24 on the other side is started for water spraying and quenching, thereby achieving the effect of improving surface hardness.

[0083] Using the above-mentioned technical solution for heat treatment, no fires or "explosions" occurred during on-site operations. The large gear of the ball mill (coal mill) underwent on-site online surface hardening and strengthening treatment in a safe and rapid manner. Testing revealed that the workpiece surface was heated to the quenching temperature with a flame, followed by rapid cooling with cooling water to achieve a high-hardness surface and favorable internal stress distribution, improving the workpiece's wear resistance and fatigue strength. The results were considerable and effective.

[0084] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

[0085] Although this paper extensively uses the following components: walking base 1, bracket 11, linear track 12, linear actuator 13, integrated flame heating and water cooling nozzle 2, upper bracket 21, lower bracket 22, flame jet section 23, flame nozzle 231, transition conical channel 232, water spray section 24, first water spray branch pipe 241, second water spray branch pipe 242, water spray hole 243, adjusting nut 25, set screw 26, circulating cooling water pipe 27, welding torch 3, and oxygen storage tank 3 1. Terms including: oxygen manifold 311, oxygen cylinder 312, acetylene storage tank 32, acetylene manifold 321, acetylene cylinder 322, mixer output 33, water inlet pipe 4, water pump 41, water tank 42, water outlet pipe 43, water receiving tray 44, return water pipe 45, control valve 46, temperature sensor 5, temperature controller 6, two-position three-way reversing valve 8, integrated quick-connect gas-water distribution plate 9, spray water distribution pipe 91, cooling circulating water distribution pipe 92, gas path distribution pipe 93, etc. The use of these terms is merely for the convenience of describing and explaining the essence of the invention; interpreting them as any additional limitation would contradict the spirit of the invention.

Claims

1. A large gear tooth surface on-site quenching apparatus characterized by, The utility model relates to a flame heating water cooling integrated nozzle, which comprises a walking base (1) and a flame heating water cooling integrated nozzle (2) arranged on the walking base (1). The walking base (1) is connected with a linear driver (13) provided with a speed adjusting device, and a temperature sensor (5) is arranged on the walking base (1) and connected with the speed adjusting device of the linear driver (13) through a temperature controller (6) to control the linear driver (13) to accelerate when the temperature of the temperature sensor (5) is higher than the set range of the temperature controller (6) and to control the linear driver (13) to decelerate when the temperature of the temperature sensor (5) is lower than the set range of the temperature controller (6). The side of the flame spraying part (23) is provided with a circulating cooling water pipe (27), the inlet end of the circulating cooling water pipe (27) is connected with the water inlet pipe (4), and the outlet end is connected with a water outlet pipe (43); the flame spraying part (23) on the upper support (21) and the lower support (22) is respectively in a U shape, the circulating cooling water pipe (27) is arranged outside the flame spraying part (23), and the water spraying part (24) is arranged outside the circulating cooling water pipe (27); the water spraying part (24) comprises a first water spraying branch pipe (241) and a second water spraying branch pipe (242) arranged on the two sides of the flame spraying part (23) respectively, the first water spraying branch pipe (241), the second water spraying branch pipe (242) and the water inlet pipe (4) are connected through a two-position three-way reversing valve (8), and the walking base (1) drives the flame heating water cooling integrated nozzle (2) to move laterally and reciprocally. The flame nozzles (231) are arranged in several rows in a staggered manner, each row of the flame nozzles (231) is arranged in a front-to-back direction along the flame spraying part (23), and the flame parts of adjacent flame nozzles (231) in each row of the flame nozzles (231) are partially overlapped or connected. The distance between adjacent flame nozzles (231) in each row of the flame nozzles (231) gradually increases from front to back.

2. A large gear tooth surface quenching apparatus as claimed in claim 1, characterized in that: The outlet of the flame nozzle (231) has a transition conical channel (232) gradually increasing from inside to outside.

3. A large gear tooth surface quenching apparatus as claimed in claim 2, wherein: The rear ends of the upper support (21) and the lower support (22) are hingedly connected, the upper support (21) and the lower support (22) are fixed through an adjusting nut (25) and a jackscrew (26) to adjust the included angle between the upper support (21) and the lower support (22).

4. A large gear tooth surface quenching apparatus as set forth in claim 1, characterized by: The oxygen storage tank (31) is connected with a plurality of oxygen cylinders (312) through an oxygen busbar (311), and the acetylene storage tank (32) is connected with a plurality of acetylene cylinders (322) through an acetylene busbar (321).

5. An apparatus for case hardening a gear tooth surface of a large gear as defined in claim 1 wherein: ​ 6. An apparatus for case hardening a gear tooth surface of a large gear as defined in claim 1 wherein: ​

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