A leveling device with auxiliary heating function and method thereof

Abstract

The present invention discloses a leveling device with an auxiliary heating function and a method thereof, comprising a leveling machine connected by a first water pipe assembly and a first wire assembly, and an auxiliary heating device installed on the front side of a mobile trolley of the leveling machine. The leveling machine comprises a variable frequency power supply, a chiller, and a mobile trolley; the chiller is connected to the variable frequency power supply through a second water pipe assembly, and the variable frequency power supply is connected to the mobile trolley through a third water pipe assembly; the variable frequency power supply is arranged above the chiller, and an embedded system-on-chip is provided inside the variable frequency power supply for controlling the auxiliary heating device; the mobile trolley is equipped with a coaxial transformer and an electromagnetic induction heating coil, the coaxial transformer reduces the input current of the variable frequency power supply to a safe voltage range, and the electromagnetic induction heating coil operates on the leveling area through the principle of electromagnetic induction. The present invention can collect the heat generated by the variable frequency power supply and the mobile trolley during operation, and can provide auxiliary heating for the leveling area, thereby effectively improving the energy utilization efficiency of the leveling device.

Description

Technical Field

[0001] The present invention belongs to the technical field of welding deformation leveling, and in particular relates to a leveling device with an auxiliary heating function and a method thereof. Background Art

[0002] Ship and offshore structures are primarily connected using fusion welding. The uneven, localized heating of the steel by the welding arc inevitably causes stress and deformation in these structures. Traditional pyrotechnic straightening processes present numerous challenges, including high operator experience requirements, high uncertainty in leveling results, the generation of toxic gases during heating, which significantly impacts the environment, and the safety risks associated with the storage of the required fuel. Furthermore, the labor intensity and environmental impact of pyrotechnic straightening methods are high, resulting in a declining number of professionals willing to pursue this profession.

[0003] While high-frequency induction heating technology holds broad promise for industrial applications due to its clean, efficient, and easy-to-use advantages, current high-frequency heating and leveling devices suffer from low energy efficiency, consuming significant amounts of energy during the heating and leveling process. This is primarily due to climatic conditions, where steel plate temperatures can be significantly lower in winter than in summer, exacerbating energy consumption. Furthermore, high-frequency heating devices require adjustments to current parameters such as frequency and voltage, generating significant heat and increasing energy consumption.

[0004] Chinese Patent No. 202110570261.7 discloses an integrated high-frequency intelligent leveling machine. The overall leveling machine frame is divided into three layers: an intelligent heating mechanism, a chiller mechanism, and a high-frequency power supply mechanism. These three layers are coordinated and controlled by a main controller. The overall leveling machine frame includes two pairs of wheels driven by servo motors, a push rod at the upper rear of the power supply frame, a control panel in front of the push rod, and a three-phase AC outlet below the push rod for power supply operation. The intelligent heating mechanism heats the machine using electromagnetic induction heating. The chiller mechanism cools the high-frequency power supply mechanism and the intelligent heating mechanism through a water-cooling pipe assembly. The high-frequency power supply mechanism converts three-phase AC power into the current required by the intelligent heating mechanism through its internal components. However, when the variable frequency power supply converts the current and the intelligent heating mechanism heats and levels the steel plate, the device consumes a large amount of energy, which is dissipated as heat. Using the chiller mechanism to cool the high-frequency power supply and intelligent heating mechanism only prevents the heat from affecting the device itself, but it wastes a significant amount of energy and reduces energy efficiency. Summary of the Invention

[0005] The purpose of the present invention is to overcome the defects of the prior art and provide a leveling device and method with auxiliary heating function. The present invention can utilize the thermal energy in the water to assist in heating the area to be leveled during the process of the chiller dissipating heat for the leveling machine, and utilize the system's own energy to improve the energy utilization efficiency of the leveling device.

[0006] In order to achieve the above objectives, the present invention adopts the following technical solutions.

[0007] A leveling device with an auxiliary heating function includes a leveling machine and an auxiliary heating device. The leveling machine operates on the leveling area using the principle of electromagnetic induction heating. The auxiliary heating device collects heat generated by the leveling machine during operation to auxiliary heat the area to be leveled. The leveling machine and the auxiliary heating device are connected via a first water pipe assembly and a first wire assembly. The auxiliary heating device is installed on the front side of the mobile trolley of the leveling machine.

[0008] The leveling machine includes a variable frequency power supply, a chiller, and a mobile trolley; the chiller is connected to the variable frequency power supply through a second water pipe assembly, and the variable frequency power supply is connected to the mobile trolley through a third water pipe assembly to form a loop, thereby cooling the variable frequency power supply and the mobile trolley; the variable frequency power supply is arranged above the chiller, and provides the power required by the chiller through a second wire assembly, which is used to convert the input current into a high-frequency and high-voltage form, and transmit it to the mobile trolley through the third wire assembly; an embedded on-chip system is provided inside the variable frequency power supply for controlling the auxiliary heating device; a coaxial transformer and an electromagnetic induction heating coil are installed in the mobile trolley, the coaxial transformer is used to reduce the input current of the variable frequency power supply to a safe voltage range, and the electromagnetic induction heating coil operates on the leveling area through the principle of electromagnetic induction.

[0009] Furthermore, the auxiliary heating device includes an outer shell and a hot water tank arranged in the middle and lower part of the outer shell; the upper part of the hot water tank is connected to the upper inner part of the outer shell by a retractable part; on both sides of the hot water tank, insulating rubber, electromagnet, and insulating guide rail are arranged in sequence; the insulating guide rail is fixed to the inner side of the outer shell, and the electromagnet slides with the insulating guide rail; the electromagnet, insulating rubber and hot water tank are fixedly connected to each other.

[0010] Preferably, four springs are evenly distributed on the upper part of the hot water tank, one end of which is fixed to the upper part of the inner side of the shell, and the other end is fixed to the upper part of the outer side of the hot water tank.

[0011] Preferably, the insulating rubber and the hot water tank are fixedly connected to each other using copper screws.

[0012] Furthermore, the variable frequency power supply is packaged separately and arranged above the outer side of the chiller.

[0013] Specifically, the chiller includes a first water tank and a second water tank, which are respectively arranged on both sides of the interior of the chiller body; a heat exchanger is installed between the first water tank and the second water tank of the chiller, and an electric heater is arranged on the left side of the interior of the second water tank.

[0014] A leveling method with auxiliary heating function, using the above-mentioned leveling device, includes the following steps:

[0015] Step 1: Connect the power supply, start the leveler, and rotate to start the variable frequency power supply;

[0016] Step 2: Press the button on the variable frequency power supply to start the chiller;

[0017] Step 3: Push the leveler to the work area and start the heating function. The variable frequency power supply converts the input three-phase electricity into high-frequency and high-voltage electricity. The electricity is then transmitted to the mobile carriage through the third wire assembly. After conversion by the coaxial transformer, it is transmitted to the electromagnetic induction heating coil. The electromagnetic induction heating coil generates eddy currents on the steel plate through the magnetic field, thereby achieving a heating effect and operating the leveling area.

[0018] Step 4: The chiller starts working. The cooling water in the first water tank of the chiller is pumped out by the water pump, flows through the area that needs to be cooled, and then returns to the first water tank of the chiller. The heat exchanger transfers the temperature in the first water tank of the chiller to the second water tank of the chiller. If the water temperature in the second water tank of the chiller is low, an electric heater can be used to heat it.

[0019] Step 5: The embedded on-chip system in the variable frequency power supply controls the electromagnet in the auxiliary heating device to be energized, generating suction, which makes the bottom surface of the hot water tank fit with the area to be heated and leveled, and uses the water temperature for auxiliary heating. When the position needs to be moved, the button on the variable frequency power supply can be pressed to de-energize the electromagnet, and the position can be moved.

[0020] Step 6: After the heat exchanger transfers the heat of the water in the first water tank of the chiller to the second water tank of the chiller, the water pump continuously pumps water. The cooling water in the first water tank of the chiller enters the evaporator under the action of pressure, transfers the remaining heat to the refrigerant, and returns to the first water tank of the chiller, completing the water cycle;

[0021] Step 7. After heating is completed, turn off the power, unplug the three-phase AC plug, and drain the water in the chiller.

[0022] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0023] 1. The present invention uses an auxiliary heating device to collect the heat generated by the variable frequency power supply and the mobile trolley during operation, stores the heat in water, and applies it to auxiliary heating of the area to be leveled through components such as water pipes. By recycling energy, the energy consumed by the leveling machine is reduced, thereby improving energy utilization efficiency.

[0024] 2. The auxiliary heating device of the present invention is provided with an electric heater inside, which has the ability of independent auxiliary heating and is suitable for situations where the leveling device is used for a short time.

[0025] 3. An auxiliary heating device of the present invention uses an electromagnet, which can make the auxiliary heating device fit more closely with the leveling area. The electromagnet and the spring constitute a component that can remotely control the fitting and adsorption of the auxiliary heating device and the leveling area, with a high degree of automation and good control effect.

[0026] 4. The variable frequency power supply of the present invention is separately packaged and installed above the outside of the chiller, thereby separating the chiller from the variable frequency power supply, avoiding safety hazards caused by water leakage from the chiller. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 The present invention relates to a leveling device with an auxiliary heating function.

[0028] Figure 2 It is a structural schematic diagram of a leveling machine according to an embodiment of the present invention.

[0029] Figure 3 Schematic diagram of the structure of an auxiliary heating device according to an embodiment of the present invention.

[0030] Figure 4 This is a working principle diagram of a water chiller according to an embodiment of the present invention.

[0031] Figure 5 This is a working principle diagram of an auxiliary heating device according to an embodiment of the present invention.

[0032] Among them, there are a leveling machine 10, an auxiliary heating device 20, a variable frequency power supply 11, a chiller 12, a mobile trolley 13, a shell 21, an electromagnet 22, an insulating guide rail 23, an insulating rubber 24, a hot water tank 25, a spring 26, a copper screw 27, a first water pipe assembly 31, a first wire assembly 32, a second water pipe assembly 33, a second wire assembly 34, a third water pipe assembly 35, and a third wire assembly 36. DETAILED DESCRIPTION

[0033] The present invention will be further described in detail below with reference to the accompanying drawings.

[0034] like Figure 1As shown, a leveling device with auxiliary heating function of the present invention includes a leveling machine 10 and an auxiliary heating device 20. The leveling machine 10 operates on the leveling area through the principle of electromagnetic induction heating. The auxiliary heating device 20 collects the heat generated by the leveling machine 10 during operation to auxiliary heat the area to be leveled. The leveling machine 10 and the auxiliary heating device 20 are connected through a first water pipe assembly 31 and a first wire assembly 32. The auxiliary heating device 20 is installed on the front side of the mobile cart 13 of the leveling machine 10.

[0035] like Figure 2 As shown, a leveling machine 10 of an embodiment of the present invention includes a variable frequency power supply 11, a chiller 12, a mobile trolley 13, a second water pipe assembly 33, a second wire assembly 34, a third water pipe assembly 35 and a third wire assembly 36; the chiller 12 is connected to the variable frequency power supply 11 through the second water pipe assembly 33, and the variable frequency power supply 11 is connected to the mobile trolley 13 through the third water pipe assembly 35, forming a loop to cool the variable frequency power supply 11 and the mobile trolley 13; the variable frequency power supply 11 is installed above the chiller 12 (the variable frequency power supply 11 is separately packaged and placed above the outer side of the chiller 12), and the power required by the chiller 12 is provided through the second wire assembly 34, which is mainly used to convert the input current into a high frequency and high voltage form, and transmit it to the mobile trolley 13 through the third wire assembly 36. The variable frequency power supply 11 is equipped with an embedded system-on-chip (SoC) for controlling the auxiliary heating device 20. The mobile cart 13 houses a coaxial transformer and electromagnetic induction heating coil. The coaxial transformer reduces the current transmitted from the variable frequency power supply 11 to a safe voltage range, while the electromagnetic induction heating coil operates on the leveling area through the principle of electromagnetic induction. The operating principle is as follows: After passing through the variable frequency power supply 11, the three-phase current is converted into a high-frequency, high-voltage current. This high-frequency, high-voltage current is then transmitted to the coaxial transformer and electromagnetic induction heating coil within the mobile cart 13. The coaxial transformer converts the high-frequency, high-voltage current into a high-frequency, low-voltage current. This current passing through the electromagnetic induction heating coil generates powerful induced currents, or eddy currents, in the leveling area, generating significant Joule heating energy, thereby achieving a smooth surface in the leveling area. The chiller 12 is used to transfer heat from the variable frequency power supply 11 and the mobile cart 13.

[0036] like Figure 3 As shown, the auxiliary heating device 20 of an embodiment of the present invention is Figure 2The full cross-sectional view at point AA in the middle shows a housing 21 and a hot water tank 25 located in the lower-middle portion of the housing 21. The upper portion of the hot water tank 25 is connected to the upper inner portion of the housing 21 via a retractable member, preferably a spring. Four springs 26 can be evenly distributed above the hot water tank 25, one end of which is fixed to the upper inner portion of the housing 21 and the other end to the upper outer portion of the hot water tank 25. On either side of the hot water tank 25, an insulating rubber 24, an electromagnet 22, and an insulating guide rail 23 are arranged in sequence. The insulating guide rail 23 is fixed to the inner portion of the housing 21, and the electromagnet 22 slidably engages with the insulating guide rail 23. The electromagnet 22, insulating rubber 24, and hot water tank 25 are fixedly connected to each other. Copper screws 27 are preferably used to secure the electromagnet 22, insulating rubber 24, and hot water tank 25 together. The electromagnet 22 and the spring 26 form a component that can control the adsorption of the hot water tank and the steel plate: when the electromagnet 22 is energized, it generates magnetic force, which can drive the hot water tank 25 to move downward. When the electromagnet 22 is de-energized, the hot water tank 25 can return to its original position under the action of the spring 26. Figure 5 As shown, the chiller includes a first water tank and a second water tank, located on either side of the chiller housing. A heat exchanger is installed between the first and second water tanks to transfer heat from the water in the first tank to the second tank. An electric heater is installed on the left side of the second tank to increase the water temperature. The first water tank absorbs heat generated by the variable frequency power supply and the mobile trolley through a pipe loop. The second water tank is connected to an auxiliary heating device via a pipe to provide auxiliary heating for the area to be leveled. Its working principle is as follows: the cooling water in the first water tank of the chiller is pumped out by the water pump, flows through the area that needs to be cooled (the variable frequency power supply 11 and the mobile cart 12), and finally returns to the first water tank of the chiller. The heat exchanger transfers the temperature to the second water tank of the chiller. The water temperature in the second water tank of the chiller increases, and the hot water is transported to the hot water tank 25 through the first water pipe assembly 31 for auxiliary heating. If the temperature in the hot water tank 25 is low, the electric heater can increase the temperature of the water in the second water tank of the chiller, and transport the hot water to the hot water tank 25 through the first water pipe assembly 31 for auxiliary heating.

[0037] like Figure 4FIG2 is a schematic diagram showing the working principle of a water chiller according to an embodiment of the present invention. The water chiller 12 includes three interconnected systems: a refrigerant circulation system, a water circulation system, and an electrical automatic control system. The refrigerant circulation system refers to the following: the liquid refrigerant in the evaporator absorbs heat from the water and begins to evaporate. Eventually, the liquid refrigerant completely evaporates and becomes gaseous, which is then sucked into the condenser by the compressor. The gaseous refrigerant releases heat through the condenser and condenses into liquid. After passing through the drying filter and the expansion valve for throttling, it becomes low-temperature, low-pressure refrigerant and enters the evaporator, completing the refrigerant circulation process. The water circulation system refers to the water pump that pumps water from the first water tank of the water chiller to the equipment to be cooled (electromagnetic induction coil, etc.). The water removes heat and its temperature rises. After transferring the heat to the refrigerant in the evaporator, it returns to the first water tank of the water chiller, completing the water circulation. The electrical automatic control system mainly includes a power supply unit and an automatic control unit. The power supply unit supplies power to the various components in the water chiller 12. The automatic control unit refers to the thermostat, pressure protection, etc., which are combined to make the water chiller 12 safer during use.

[0038] A leveling method with auxiliary heating function of the present invention comprises the following steps:

[0039] Step 1: Connect the power supply, start the leveler 10, rotate the knob of the variable frequency power supply 11, and turn on the variable frequency power supply 11;

[0040] Step 2: Press the button on the variable frequency power supply 11 to start the chiller 12;

[0041] Step 3: Push the leveler 10 to the area where work is required and start the heating function. The variable frequency power supply 11 converts the input three-phase electricity into high-frequency and high-voltage electricity. The electricity is then transmitted to the mobile carriage 13 via the third wire assembly 36. After conversion by the coaxial transformer, it is transmitted to the electromagnetic induction heating coil. The electromagnetic induction heating coil generates eddy currents on the steel plate through the magnetic field, thereby achieving a heating effect and operating the leveling area.

[0042] Step 4: The chiller 12 starts working. The cooling water in the first water tank of the chiller is pumped out by the water pump, flows through the area that needs to be cooled, and then returns to the first water tank of the chiller. The heat exchanger transfers the temperature in the first water tank of the chiller to the second water tank of the chiller. If the water temperature in the second water tank of the chiller is low, an electric heater can be used to heat it.

[0043] Step 5: The embedded system-on-chip in the variable frequency power supply 11 controls the electromagnet 22 in the auxiliary heating device 20 to be energized, generating suction, which brings the bottom surface of the hot water tank 25 into contact with the area to be heated and leveled, utilizing the water temperature for auxiliary heating. When the position needs to be moved, the electromagnet 22 can be de-energized by pressing a button on the variable frequency power supply 11, thereby enabling the position to be moved.

[0044] Step 6: After the heat exchanger transfers the heat of the water in the first water tank of the chiller to the second water tank of the chiller, the water pump continuously pumps water. The cooling water in the first water tank of the chiller enters the evaporator under the action of pressure, transfers the remaining heat to the refrigerant, and returns to the first water tank of the chiller, completing the water cycle;

[0045] Step 7: After heating is completed, turn off the power, unplug the three-phase AC plug, and drain the water in the chiller 12.

Claims

1. A leveling device with auxiliary heating function, characterized in that: The invention comprises a leveling machine (10) and an auxiliary heating device (20), wherein the leveling machine (10) operates on the leveling area by the electromagnetic induction heating principle, and the auxiliary heating device (20) collects the heat generated by the leveling machine (10) during operation to perform auxiliary heating on the area to be leveled, and the leveling machine (10) and the auxiliary heating device (20) are connected via a first water pipe assembly (31) and a first wire assembly (32), and the auxiliary heating device (20) is installed on the front side of a movable trolley (13) of the leveling machine (10); The leveling machine (10) includes a variable frequency power supply (11), a chiller (12), and a mobile trolley (13); the chiller (12) is connected to the variable frequency power supply (11) through a second water pipe assembly (33), and the variable frequency power supply (11) is connected to the mobile trolley (13) through a third water pipe assembly (35), forming a loop, thereby cooling the variable frequency power supply (11) and the mobile trolley (13); the variable frequency power supply (11) is arranged above the chiller (12), and provides the chiller (13) with a second wire assembly (34). 2) A required power supply is used to convert the input current into a high-frequency and high-voltage form and transmit it to the mobile trolley (13) through a third wire assembly (36); an embedded system-on-chip is provided inside the variable frequency power supply (11) for controlling the auxiliary heating device (20); a coaxial transformer and an electromagnetic induction heating coil are installed in the mobile trolley (13), the coaxial transformer is used to reduce the input current of the variable frequency power supply (11) to a safe voltage range, and the electromagnetic induction heating coil operates on the leveling area through the electromagnetic induction principle; The auxiliary heating device (20) comprises a shell (21) and a hot water tank (25) arranged in the middle and lower part of the shell; the upper part of the hot water tank (25) is connected to the upper inner part of the shell (21) by a telescopic member; insulating rubber (24), an electromagnet (22), and an insulating guide rail (23) are arranged in sequence on both sides of the hot water tank (25); the insulating guide rail (23) is fixed to the inner side of the shell (21), and the electromagnet (22) and the insulating guide rail (23) are slidably matched; the electromagnet (22), the insulating rubber (24), and the hot water tank (25) are fixedly connected to each other.

2. A leveling device with auxiliary heating function according to claim 1, characterized in that: Four springs (26) are evenly distributed on the upper part of the hot water tank (25), one end of which is fixed to the upper part of the inner side of the shell (21), and the other end is fixed to the upper part of the outer side of the hot water tank (25).

3. The leveling device with auxiliary heating function according to claim 2, characterized in that: The insulating rubber (24) and the hot water tank (25) are fixedly connected to each other by using copper screws (27).

4. The leveling device with auxiliary heating function according to claim 1, characterized in that: The variable frequency power supply (11) is packaged separately and arranged above the outer side of the chiller (12).

5. The leveling device with auxiliary heating function according to claim 1, characterized in that: The chiller includes a first water tank and a second water tank, which are respectively arranged on both sides of the chiller body; a heat exchanger is installed between the first water tank and the second water tank of the chiller, and an electric heater is arranged on the left side of the second water tank.

6. A leveling method with auxiliary heating function, using the leveling device according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step 1: Connect the power supply, start the leveling machine (10), and rotate and start the variable frequency power supply (11); Step 2: Press the button on the variable frequency power supply (11) to start the chiller (12); Step 3: Push the leveling machine (10) to the working area, start the heating function, and the variable frequency power supply (11) converts the input three-phase electricity into a high-frequency and high-voltage form, and then transmits it to the mobile car (13) through the third wire assembly (36). After conversion by the coaxial transformer, it is transported to the electromagnetic induction heating coil. The electromagnetic induction heating coil generates eddy currents on the steel plate through the magnetic field to achieve a heating effect, and operates the leveling area; Step 4: The chiller (12) starts working. The cooling water in the first water tank of the chiller is pumped out by the water pump, flows through the area that needs to be cooled, and then returns to the first water tank of the chiller. The heat exchanger transfers the temperature of the first water tank of the chiller to the second water tank of the chiller. If the temperature in the second water tank of the chiller is lower, an electric heater can be used to heat it. Step 5: The embedded system-on-chip in the variable frequency power supply (11) controls the electromagnet (22) in the auxiliary heating device (20) to be energized, thereby generating suction, and fitting the bottom surface of the hot water tank (25) to the area to be heated and leveled, thereby utilizing the water temperature for auxiliary heating; when the position needs to be moved, the electromagnet (22) can be de-energized by pressing a button on the variable frequency power supply (11), thereby enabling the position to be moved; Step 6: After the heat exchanger transfers the heat of the water in the first water tank of the chiller to the second water tank of the chiller, the water pump continuously pumps water. The cooling water in the first water tank of the chiller enters the evaporator under the action of pressure, transfers the remaining heat to the refrigerant, and returns to the first water tank of the chiller, completing the water cycle; Step 7: After heating is completed, turn off the power supply, unplug the three-phase AC plug, and drain the water in the chiller (12).

Images