A BD roller vertical surfacing device and surfacing method

Abstract

This invention discloses a vertical BD roller surfacing device and method, belonging to the field of BD roller surfacing technology. It includes a foundation, a rotating mechanism mounted above the foundation that enables the BD roller to be repaired to rotate vertically, several heating furnaces surrounding the BD roller, several adjustable welding platforms located outside the heating furnaces, several surfacing welding units mounted on the welding platforms, and a control system. Each heating furnace has a slag removal window. The surfacing welding units are installed at the slag removal windows on the welding platforms for welding. A slag scraper is installed in front of the weld bead and mounted on the heating furnace. The heating furnace can preheat and maintain the temperature of the BD roller to be repaired. This invention effectively solves the problems of low efficiency, high labor intensity, and waste of welding materials in BD roller surfacing.

Description

Technical Field

[0001] This invention relates to the field of BD roller surfacing technology, and in particular to a BD roller vertical surfacing device and surfacing method. Background Technology

[0002] BD rolls experience significant wear during rolling due to contact with high-temperature steel. Currently, horizontal welding machines are primarily used to restore the worn pass profiles to their original dimensions for reuse. However, due to the depth of the passes, only one welding head is used per face. Furthermore, the steepness of the face (approximately 90 degrees) makes welding difficult, requiring one person per face for edge trimming, resulting in high labor costs and low automation. Considering the spacing between welding heads, a maximum of two welding power sources are used, further reducing efficiency. Additionally, the wear on these face profiles is generally minimal, around 5-6mm. Using traditional horizontal submerged arc welding, a single pass thickness is only about 30mm, requiring the extra 24-25mm to be machined away, leading to significant waste of welding materials. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a BD roller vertical surfacing device and surfacing method to solve the problems of low efficiency, high labor intensity and waste of welding materials in BD roller surfacing.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0005] A vertical BD roller surfacing device includes a foundation, a rotating mechanism mounted above the foundation that enables the BD roller to be repaired to rotate vertically, several heating furnaces surrounding the BD roller to be repaired, several layers of welding platforms with adjustable height mounted outside the heating furnaces, several surfacing welding units mounted on the welding platforms, and a control system. Each heating furnace has a slag removal window. The surfacing welding units are mounted on the welding platforms at the slag removal windows for welding. A slag scraper is mounted in front of the weld bead and installed on the heating furnace. The heating furnaces are capable of preheating and maintaining the temperature of the BD roller to be repaired.

[0006] A further improvement of the technical solution of the present invention is that: the heating furnace is set to 4, and the top of the heating furnace is sealed to reduce the process heat replenishment.

[0007] A further improvement of the technical solution of the present invention is that the welding platform is set to 4 layers, with each layer spaced 700-800mm apart.

[0008] A further improvement of the technical solution of the present invention is that the basic equipment includes a top tip that can support the bottom end of the BD roller to be repaired, a support base for a heating furnace set outside the top tip, a support frame for a welding platform, and a slag trough for receiving welding slag.

[0009] A further improvement of the technical solution of the present invention is that: the upper end of the BD roller to be repaired is fixedly connected to the tray of the rotating mechanism, and the center of the lower end face of the BD roller to be repaired stands on the top point in the middle of the foundation.

[0010] A further improvement of the technical solution of the present invention is that: one set of surfacing welding machine group is arranged at each of the four welding slag removal windows on each welding platform, and each set of surfacing welding machine group is equipped with four welding machine heads for welding. Based on the setting of four welding platforms, it is possible to realize surfacing welding operations by 64 welding machine heads at the same time.

[0011] A further improvement to the technical solution of the present invention is that the welding machine heads at the same position on each welding platform are fixed on the same support plate, a fine-tuning mechanism is added, and the number of welding machine heads is optimized.

[0012] A welding method for a BD roller vertical welding device includes the following steps:

[0013] Step 1: Set up the foundation and make tooling on the BD roller conveyor end to be repaired so that the BD roller to be repaired can be vertically hoisted.

[0014] Step 2: Vertically assemble the BD roller to be repaired onto the rotating mechanism, and keep the BD roller to be repaired rotating at 4-10 r / h.

[0015] Step 3: Assemble the heating furnace and preheat the BD roller to be repaired to 200-300℃;

[0016] Step 4: Set up a welding platform, install a surfacing welding unit on the welding platform, and fix a slag scraper on the heating furnace in front of the weld bead of the surfacing welding unit.

[0017] Step 5: Use a welding surfacing unit to perform welding on the BD roller to be repaired. The welding slag generated during the process is scraped off by a welding slag scraper, realizing automatic cleaning of welding slag.

[0018] The technological advancements achieved by this invention due to the adoption of the above technical solutions are as follows:

[0019] 1. This invention improves the production efficiency of BD roll surfacing welding. The original horizontal surfacing welding machine tool takes about 20 days to weld a 20-ton BD roll, while the vertical BD roll surfacing welding device of this invention can be completed in about 7 days, greatly reducing the remanufacturing cycle.

[0020] 2. This invention reduces the amount of welding material applied to the vertical edge of the BD roll during the welding process. Previously, a horizontal welding machine required approximately 3-4 tons of welding material to weld a 20-ton BD roll, with the excess (24mm-25mm) having to be machined off. However, using the vertical BD roll welding device of this invention, the welding material can be reduced to 2-3 tons, significantly reducing the amount of welding material and keeping the welding allowance essentially within 2mm-3mm.

[0021] 3. This invention changes the vertical edge welding process of the BD roller to horizontal welding, reducing labor intensity. The original horizontal welding machine required approximately two people to weld a 20-ton BD roller, while the vertical BD roller welding device of this invention only requires one person to operate, significantly reducing labor intensity. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a top view cross-sectional schematic diagram of the BD roller vertical overlay welding device in an embodiment of the present invention;

[0024] Figure 2 This is a partial schematic diagram of the BD roller vertical surfacing welding device in an embodiment of the present invention. Figure 1 ;

[0025] Figure 3 This is a partial schematic diagram of the BD roller vertical surfacing welding device in an embodiment of the present invention. Figure 2 ;

[0026] Among them, 1. BD roller to be repaired, 2. Welding slag removal window, 3. Furnace, 4. Welding surfacing unit, 5. Welding slag scraper, 6. Rotating mechanism, 7. Welding platform. Detailed Implementation

[0027] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification, claims and accompanying drawings of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such processes, methods, products or devices.

[0028] This application provides a vertical BD roller surfacing device and method, which solves the problems of "low BD roller surfacing efficiency, high labor intensity, and waste of welding materials" in the prior art. The general idea is as follows: the device consists of four main parts: a foundation, a rotating mechanism, a heating furnace, and a surfacing welding unit. The BD roller to be repaired is vertically rotated by the rotating mechanism. Several heating furnaces that can preheat the BD roller to be repaired are set around the BD roller to be repaired. Several welding platforms that can be adjusted in height are set outside the heating furnaces. Welding slag removal windows are opened between each heating furnace. Surfacing welding units are installed at the welding slag removal windows of the welding platforms, enabling multiple surfacing welding units to simultaneously surfacing and repair the BD roller to be repaired.

[0029] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments:

[0030] like Figure 1-3 As shown, a BD roller vertical surfacing device includes a foundation and a structure set above the foundation.

[0031] The system includes a rotating mechanism 6 that enables the BD roller 1 to be repaired to rotate vertically, several heating furnaces 3 arranged around the BD roller 1 to be repaired, several layers of welding platforms 7 arranged outside the heating furnaces 3 with adjustable height, several surfacing welding units 4 installed on the welding platforms, and a control system; each heating furnace 3 is provided with a welding slag removal window 2; the surfacing welding units 4 are installed on the welding platform 7 at the welding slag removal window 2 for welding; a slag scraper 5 is provided in front of the weld bead, and the slag scraper 5 is installed on the heating furnace 3; the heating furnace 3 can preheat and keep the BD roller 1 to be repaired at a certain temperature.

[0032] Furthermore, four heating furnaces 3 are provided, and the top of each heating furnace 3 is sealed to reduce process heat replenishment.

[0033] Furthermore, the welding platform 7 is configured with 4 layers, with each layer spaced 700-800mm apart. The length of the BD roller 1 to be repaired is generally about 3m, so 4 layers are optimal. However, the number of layers and the spacing between each layer can be adjusted according to the actual site conditions.

[0034] Furthermore, the foundation includes a top point capable of supporting the bottom end of the BD roller 1 to be repaired, a support base for the heating furnace 3 located outside the top point, a support frame for the welding platform 7, and a slag trough for receiving welding slag. Specifically, the foundation can be located underground to prevent the welding platform 7 from being too high, which would make installation and welding inconvenient.

[0035] Furthermore, the upper end of the BD roller 1 to be repaired is fixedly connected to the tray of the rotating mechanism 6, and the center of the lower end face of the BD roller 1 to be repaired stands on the top point in the middle of the foundation.

[0036] Furthermore, a set of welding surfacing machine group 4 is arranged at each of the four welding slag removal windows 2 on each welding platform 7. Each set of welding surfacing machine group 4 is equipped with 4 welding machine heads for welding. Based on the setting of four welding platforms 7, it is possible to achieve 64 welding machine heads to perform surfacing operations at the same time.

[0037] Furthermore, the welding machine heads at the same position on each welding platform 7 are fixed on the same support plate, and a fine-tuning mechanism is added to optimize the number of welding machine heads.

[0038] A welding method for a BD roller vertical welding device includes the following steps:

[0039] Step 1: Set up the foundation and make tooling on the transmission end of the BD roller 1 to be repaired so that the BD roller 1 to be repaired can be vertically hoisted.

[0040] Step 2: Vertically assemble the BD roller 1 to be repaired onto the rotating mechanism 6, so that the BD roller 1 to be repaired rotates at 4-10 r / h.

[0041] Step 3: Assemble heating furnace 3 and preheat the BD roller 1 to be repaired to 200-300℃;

[0042] Step 4: Erect welding platform 7, install welding unit 4 on welding platform 7, and fix slag scraper 5 on heating furnace 3 in front of weld bead of welding unit 4; the setting of slag scraper 5 realizes automatic slag removal and reduces personnel occupation. This application changes the vertical edge welding process of BD roller to horizontal welding, reducing labor intensity. The original horizontal welding machine tool requires about 2 people to weld a 20-ton BD roller, while the vertical welding device of BD roller of this application only requires 1 person to operate, and the labor intensity is greatly reduced.

[0043] Step 5: The welding unit 4 is used to perform welding on the BD roller 1 to be repaired. The weld slag generated during the process is scraped off by the weld slag scraper 5, realizing automatic cleaning of the weld slag. A weld slag tank is set in the foundation, which reduces the difficulty of cleaning the weld slag after welding.

[0044] The heating of the heating furnace 3, the welding of the welding unit 4, the rotation of the rotating mechanism 6, and the lifting of the welding platform 7 are all controlled by the control system to achieve automatic or semi-automatic control and complete the repair of the BD roller 1 to be repaired.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A BD roller vertical surfacing welding device, characterized in that: Including the foundation, and what is set on top of the foundation. The system includes a rotating mechanism (6) capable of vertically rotating the BD roller (1) to be repaired; several heating furnaces (3) arranged around the BD roller (1) to be repaired; a welding platform (7) with 4 layers of independently adjustable height and a spacing of 700-800mm arranged outside the heating furnaces (3); a surfacing welding unit (4) consisting of 64 welding machine heads installed on the welding platform; and a control system; welding slag removal windows (2) are provided between each heating furnace (3); the surfacing welding unit (4) is installed at the welding slag removal windows (2) on the welding platform (7) for welding; a slag scraper (5) is provided in front of the weld bead, and the slag scraper (5) is installed on the heating furnace (3); the heating furnace (3) is capable of preheating and maintaining the temperature of the BD roller (1) to be repaired at 200-300℃; The foundation includes a top that can support the bottom of the BD roller (1) to be repaired, a support base for a heating furnace (3) set outside the top, a support frame for a welding platform (7), and a slag trough for receiving welding slag. The upper end of the BD roller (1) to be repaired is fixedly connected to the tray of the rotating mechanism (6), and the center of the lower end face of the BD roller (1) to be repaired stands on the top of the middle part of the foundation. One set of welding machine group (4) is arranged at each of the four welding slag removal windows (2) on each welding platform (7). Each set of welding machine group (4) is equipped with 4 welding machine heads for welding. According to the calculation of setting up four welding platforms (7), 64 welding machine heads can perform welding operations at the same time. The welding machine heads at the same position on each welding platform (7) are fixed on the same tray, and a fine-tuning mechanism is added to optimize the number of welding machine heads.

2. The BD roller vertical surfacing device according to claim 1, characterized in that: The heating furnace (3) is configured as 4 units, and the top of the heating furnace (3) is sealed to reduce the process heat replenishment.

3. A welding method for a BD roller vertical welding apparatus as described in claim 1 or 2, characterized in that: Includes the following steps: Step 1: Set up the foundation and make tooling at the transmission end of the BD roller (1) to be repaired so that the BD roller (1) to be repaired can be vertically hoisted. Step 2: Vertically assemble the BD roller (1) to be repaired onto the rotating mechanism (6) so that the BD roller (1) to be repaired rotates at 4-10 r / h. Step 3: Assemble the heating furnace (3) and preheat the BD roller (1) to be repaired to 200-300℃; Step 4: Set up a welding platform (7), install a welding surfacing unit (4) on the welding platform (7), and fix a slag scraper (5) on the heating furnace (3) in front of the weld bead of the welding surfacing unit (4). Step 5: Use the welding machine (4) to weld the BD roller (1) to be repaired. The welding slag generated during the process is scraped off by the welding slag scraper (5) to achieve automatic cleaning of welding slag.

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