Manufacturing and assembly process of cyclone separator

Abstract

The present invention provides a manufacturing and assembly process for a cyclone separator, wherein the manufacturing stage comprises: machining an annular process orifice plate; machining an annular process comb plate; bending a pipe into shape; manufacturing a lower annular header; manufacturing an upper annular header; the assembly stage comprises: undercutting a semicircular arc section of the process orifice plate and a semicircular arc section of the process comb plate on a first positioning line and a second positioning line; fixing the semicircular arc section of the process orifice plate and the semicircular arc section of the comb plate; forming a semicircular pipe screen; forming a plurality of pipe screen sections; placing a cylinder, an upper annular header, a lower annular header and the pipe screen sections on an assembly rack; welding the upper annular header and the lower annular header respectively; connecting the two ends of the pipes in the plurality of pipe screens to the upper annular header and the lower annular header respectively and welding them; spot-welding the semicircular arc section of the process orifice plate and the semicircular arc section of the comb plate to the pipe; and removing the semicircular arc section of the process orifice plate, the semicircular arc section of the comb plate and the assembly rack.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing processes, and in particular to a manufacturing and assembly process for a cyclone separator. Background Art

[0002] The cyclone separator is large in diameter and long in length, making it impossible to manufacture it as a whole at the factory. This requires on-site assembly. However, the cyclone separator is composed of many large components, and ensuring the dimensional accuracy of these components is difficult.

[0003] The cyclone separator consists of a cylinder and a cooling circulation system. The cylinder includes straight and tapered sections. The cooling circulation system is formed by welding numerous pipes and flat steel sheets, with pins welded to the inner wall of the cylinder. This creates numerous and concentrated welds, resulting in high heat input and significant deformation. This makes it challenging to ensure the correct weld dimensions. Furthermore, maintaining the proper dimensions of the cylinder joints and the pipe pitch is a challenge. Because each component is manufactured in separate pieces, and most are long and large, they lack rigidity and dimensional stability, making it difficult to maintain dimensional stability during lifting and handling.

[0004] In short, the difficulties in manufacturing water-cooled cyclones are concentrated in two aspects: (1) size control; (2) deformation control. Summary of the Invention

[0005] In view of the defects in the prior art, the purpose of the present invention is to provide a manufacturing and assembly process for a cyclone separator, so as to solve the problems in the background technology.

[0006] The present invention provides a manufacturing and assembly process for a cyclone separator, comprising a manufacturing stage and an assembly stage;

[0007] The manufacturing stages include:

[0008] S1. Processing an annular process orifice plate, engraving a plurality of perforation lines at equal intervals along the circumferential direction on the top of the annular process orifice plate, and processing positioning holes on the perforation lines, wherein the annular process orifice plate includes two semicircular arc segments of the process orifice plate;

[0009] S2. Processing an annular process comb plate, engraving a plurality of marking lines on the outer circumference of the process comb plate at equal intervals in the circumferential direction, processing limiting grooves on the marking lines, wherein the limiting grooves correspond to the positioning holes one by one, and the annular process comb plate includes two semicircular arc segments of the process comb plate;

[0010] S3. Manufacturing the pipe, bending the pipe to fit the shape of the cylinder, and checking it against the standard pipe;

[0011] S4. Manufacturing a lower annular header, bending two lower annular pipes into respective shapes with a bending angle of ≥182°, and welding both ends of the two lower annular pipes respectively;

[0012] S5. Manufacturing an upper annular header, bending two upper annular pipes into respective shapes with a bending angle of ≥182°, and welding both ends of the two upper annular pipes respectively;

[0013] The assembly phase includes:

[0014] S6. Carve a plurality of first positioning lines and a plurality of second positioning lines on the assembly platform, invert a semicircular arc segment of a process orifice plate on each first positioning line and make it perpendicular to the assembly platform, and invert a semicircular arc segment of a process comb plate on each second positioning line and make it perpendicular to the assembly platform;

[0015] S7, fixing the semicircular arc section of the process orifice plate and the semicircular arc section of the art comb plate on the assembly platform;

[0016] S8. Pass the pipe through the limiting groove and the corresponding positioning hole, and weld the pipe to the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate to form a semicircular tube screen.

[0017] S9, carving a plurality of dividing lines on the semicircular tube panel, and cutting the semicircular tube panel along the dividing lines to form a plurality of tube panel segments;

[0018] S10, placing the cylinder, the upper annular header, the lower annular header, and the plurality of tube panel segments on an assembly rack;

[0019] S11, welding the upper annular header and the lower annular header to the upper and lower ends of the cylinder respectively;

[0020] S12, connecting and welding the ends of the tubes in the plurality of tube panels to the upper annular header and the lower annular header, respectively, and arranging the plurality of tube panels in sequence along the circumferential direction inside the cylinder, with sealing steel plates welding and sealing two adjacent tubes;

[0021] S13, spot welding the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate to the pipe;

[0022] S14, removing the semicircular arc section of the process orifice plate, the semicircular arc section of the art comb plate and the assembly stand.

[0023] Furthermore, in step S3, a welding shrinkage allowance and a water pressure test allowance are left on the pipe.

[0024] Furthermore, in step S4, a lower air-eliminating hole is first opened on each of the lower annular pipes, and the lower air-eliminating hole is used for welding between the two lower annular pipes.

[0025] Furthermore, in step S5, an upper air-eliminating hole is first opened on each of the lower annular pipes, and the upper air-eliminating hole is used for welding between the two lower annular pipes.

[0026] Furthermore, in step S12, eight positioning tubes are first installed in sequence along the circumferential direction in the middle of the cylinder, and the positioning tubes are used to position two adjacent tubes in the circumferential direction, and then a reference line is engraved longitudinally on the inner wall of the cylinder.

[0027] Furthermore, in step S12, the pipe and the sealing steel plate are spot-welded before being welded and sealed.

[0028] Furthermore, the welding operation in step S13 adopts multi-station simultaneous welding, and the worker welds one side and then turns over to weld the other side.

[0029] Beneficial Effects: The present invention provides a manufacturing and assembly process for a cyclone separator. The design of the annular process orifice plate and annular process comb plate not only supports the inner wall of the cylinder but also limits the pitch between tubes, reducing tube deformation. Furthermore, the other operating steps and sequence ensure that the dimensions of each component meet dimensional requirements, resulting in minimal and simple tooling and relatively low manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the process of the present invention;

[0031] Figure 2 It is a side view schematic diagram of a semicircular tube panel;

[0032] Figure 3 Schematic diagram of the top view of the annular process orifice plate;

[0033] Figure 4 Schematic diagram of the top view of the annular process comb plate.

[0034] Figure numerals: 10 - pipe, 20 - annular process orifice plate, 21 - positioning hole, 30 - annular process comb plate, 31 - limiting groove. DETAILED DESCRIPTION

[0035] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0036] like Figure 1-4As shown, the present invention provides a manufacturing and assembly process for a cyclone separator, which includes a manufacturing stage and an assembly stage.

[0037] The manufacturing phase includes:

[0038] S1. Process the annular process orifice plate 20. Multiple perforation lines are carved into the top of the annular process orifice plate 20 at equal intervals along the circumference. Positioning holes 21 are drilled on the perforation lines. The annular process orifice plate 20 comprises two semicircular arc segments. To ensure sufficient rigidity and strength, a 16 mm thick steel plate is selected.

[0039] S2. Process an annular process comb plate 30. Multiple marking lines are engraved on the outer circumference of the process comb plate at equal intervals along the circumference. Inwardly extending limiting grooves 31 are formed on the marking lines. The limiting grooves 31 correspond one-to-one with the positioning holes 21. The annular process comb plate 30 includes two semicircular arc segments.

[0040] S3, manufacture pipe 10, bend pipe 10 into shape, so that it adapts to the outer shape of cylinder, and compare it with standard pipe 10. After being formed, pipe 10 also has straight section and tapered section, so as to adapt to the outer shape of cylinder.

[0041] S4. Fabricate the lower annular header by bending the two lower annular pipes separately to a bend angle of ≥182° and welding the two ends of the pipes separately. During the manufacturing process of the lower annular header, we have set special requirements for the bending process of the lower annular pipes. The lower annular header is required to be bent in two sections, with each section having a bend angle of no less than 182°. A larger bend angle is required to ensure that after removing the allowance, the two sections can be assembled and welded to form a 360° lower annular header.

[0042] S5. To manufacture the upper annular header, bend the two upper annular pipes separately to a bend angle of ≥182° and weld the two ends of the pipes separately. During the manufacturing process of the upper annular header, we have set special requirements for the bending process of the upper annular pipes. The upper annular header is required to be bent in two sections, with each section having a bend angle of no less than 182°. A larger bend angle is required to ensure that after removing the allowance, the two sections can be assembled and welded to form a 360° upper annular header.

[0043] The assembly phase includes:

[0044] S6. Mark multiple first and second positioning lines on the assembly platform. On each first positioning line, invert a semicircular arc segment of the process orifice plate and position it perpendicular to the assembly platform. On each second positioning line, invert a semicircular arc segment of the process comb plate and position it perpendicular to the assembly platform. Ensure that all semicircular arc segments of the process orifice plate are coaxial with the axis of the semicircular arc segment of the process comb plate.

[0045] S7. After the positions of the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate are determined, the cutting steel is used to tighten the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate and fix them on the assembly platform.

[0046] S8. Pass the tube 10 through the retaining slot 31 and the corresponding positioning hole 21. Weld the tube 10 to the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate to form a semicircular tube panel. Before this step, make an inlet angle bracket out of steel. When assembling the tube 10, use the inlet angle bracket as a reference to align the tube 10.

[0047] S9. Mark multiple dividing lines on the semicircular tube panel and cut the semicircular tube panel along the dividing lines to form multiple tube panel segments. Cutting along the dividing lines (including the semicircular arc segments of the process orifice plate and the process comb plate) has been proven in practice to reduce deformation of each semicircular tube panel after cutting.

[0048] S10, placing the cylinder, the upper annular header, the lower annular header and the plurality of tube panel segments on an assembly rack.

[0049] S11. Weld the upper annular header and the lower annular header to the upper and lower ends of the cylinder respectively.

[0050] S12. Connect and weld the ends of the tubes 10 within the multiple tube panels to the upper and lower annular headers, respectively. The tubes 10 are now integrated with the upper and lower annular headers. The multiple tube panels are sequentially arranged circumferentially inside the cylinder. After the fillet welds pass flaw detection, adjacent tubes 10 are welded and sealed with sealing steel plates.

[0051] S13, spot welding the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate to the pipe 10;

[0052] S14. Remove the semicircular arc section of the process orifice plate, the semicircular arc section of the art comb plate and the assembly rack.

[0053] The annular process orifice plate 20 is a key component for ensuring the proper dimensions of the cylinder interface and the pitch of the tubes 10. The pitch of the positioning holes 21 on the annular process orifice plate 20 corresponds to the pitch between the tubes 10. The center diameter of the annular process orifice plate 20 is equal to the port diameter of the cyclone separator. The cyclone separator is designed with three annular process orifice plates 20: one at the port of the straight section of the cylinder and one on each side of the section where the straight section separates from the tapered section.

[0054] The pitch of the tubes 10 in the center of the cylinder is maintained by the annular comb plates 30. An annular comb plate 30 is installed approximately every two meters. The center diameter of the annular comb plates 30 located in the straight section of the cylinder is equal to the diameter of the straight section. The center diameter of the annular comb plates 30 located in the tapered section is related to their installation location; different locations result in different center diameters.

[0055] In this process, the design of the annular process orifice plate 20 and the annular process comb plate 30 not only supports the inner wall of the cylinder, but also limits the pitch between the tubes 10, reducing the deformation of the tubes 10. At the same time, the other operating steps and operating sequence ensure that the dimensions of each component meet the dimensional requirements, the tooling is reduced and simple, and the manufacturing cost is relatively low.

[0056] In one embodiment, in step S3, a welding shrinkage allowance and a hydrostatic test allowance are left on the pipe 10. The welding shrinkage allowance can reduce deformation of the pipe 10 when welded to other components. The hydrostatic test measures the water pressure within the pipe 10 and can test the stability of the pipe 10.

[0057] In one embodiment, in step S4, a lower air-eliminating hole is first opened on each lower annular pipe, and the lower air-eliminating hole is used for welding between the two lower annular pipes. The design of the air-eliminating hole can ensure the quality of the butt welding between the two lower annular pipes.

[0058] In one embodiment, in step S5, an upper air-eliminating hole is first opened on each lower annular pipe, and the upper air-eliminating hole is used for welding between the two lower annular pipes. The design of the air-eliminating hole can ensure the quality of the butt welding between the two upper annular pipes.

[0059] In one embodiment, in step S12, eight positioning tubes are first installed in the middle of the cylinder at equal intervals along the circumferential direction. The positioning tubes are used to position two adjacent tubes 10 in the circumferential direction. Then, a reference line is longitudinally engraved on the inner wall of the cylinder.

[0060] The positioning tube is located between two adjacent tubes 10 and plays a role in positioning the tube panel segment in the circumferential direction, facilitating the accurate installation of the tube panel segment.

[0061] The longitudinally engraved reference line can play a role in positioning the tube panel section in the longitudinal direction. When operating, the staff only needs to align one of the tubes 10 with the reference line, which further facilitates the accurate installation of the tube panel section.

[0062] In one embodiment, in step S12, spot welding is performed on the pipe 10 and the sealing steel plate before welding them to seal.

[0063] In one embodiment, the welding operation in step S13 is performed by multiple stations simultaneously, and the worker welds one side and then turns over to weld the other side.

[0064] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, the embodiments should be regarded as illustrative and non-restrictive in all respects. The scope of the present invention is defined by the appended claims rather than the foregoing description, and all changes that come within the meaning and range of equivalents of the claims are intended to be included therein.

[0065] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A manufacturing and assembly process for a cyclone separator, characterized in that: It includes the manufacturing stage and the assembly stage; The manufacturing stages include: S1. Processing an annular process orifice plate, engraving a plurality of perforation lines at equal intervals along the circumferential direction on the top of the annular process orifice plate, and processing positioning holes on the perforation lines, wherein the annular process orifice plate includes two semicircular arc segments of the process orifice plate; S2. Processing an annular process comb plate, engraving a plurality of marking lines on the outer circumference of the process comb plate at equal intervals in the circumferential direction, processing limiting grooves on the marking lines, wherein the limiting grooves correspond to the positioning holes one by one, and the annular process comb plate includes two semicircular arc segments of the process comb plate; S3. Manufacturing the pipe, bending the pipe to fit the shape of the cylinder, and checking it against the standard pipe; S4. Manufacturing a lower annular header, bending two lower annular pipes into respective shapes with a bending angle of ≥182°, and welding both ends of the two lower annular pipes respectively; S5. Manufacturing an upper annular header, bending two upper annular pipes into respective shapes with a bending angle of ≥182°, and welding both ends of the two upper annular pipes respectively; The assembly phase includes: S6. Carve a plurality of first positioning lines and a plurality of second positioning lines on the assembly platform, invert a semicircular arc segment of a process orifice plate on each first positioning line and make it perpendicular to the assembly platform, and invert a semicircular arc segment of a process comb plate on each second positioning line and make it perpendicular to the assembly platform; S7, fixing the semicircular arc section of the process orifice plate and the semicircular arc section of the art comb plate on the assembly platform; S8, passing the pipe through the limiting groove and the corresponding positioning hole, and welding the pipe to the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate to form a semicircular tube screen; S9, carving a plurality of dividing lines on the semicircular tube panel, and cutting the semicircular tube panel along the dividing lines to form a plurality of tube panel segments; S10, placing the cylinder, the upper annular header, the lower annular header, and the plurality of tube panel segments on an assembly rack; S11, welding the upper annular header and the lower annular header to the upper and lower ends of the cylinder respectively; S12, connecting and welding the ends of the tubes in the plurality of tube panels to the upper annular header and the lower annular header, respectively, and arranging the plurality of tube panels in sequence along the circumferential direction inside the cylinder, with sealing steel plates welding and sealing two adjacent tubes; S13, spot welding the semicircular arc section of the process orifice plate and the semicircular arc section of the process comb plate to the pipe; S14, removing the semicircular arc section of the process orifice plate, the semicircular arc section of the art comb plate and the assembly stand.

2. The manufacturing and assembly process of a cyclone separator according to claim 1, characterized in that: In step S3, a welding shrinkage allowance and a water pressure test allowance are left on the pipe.

3. The manufacturing and assembly process of a cyclone separator according to claim 2, characterized in that: In step S4, a lower air-eliminating hole is first opened on each of the lower annular pipes, and the lower air-eliminating hole is used for welding between two lower annular pipes.

4. The manufacturing and assembly process of a cyclone separator according to claim 1, characterized in that: In step S5, an upper air-eliminating hole is first opened on each of the lower annular pipes, and the upper air-eliminating hole is used for welding between the two lower annular pipes.

5. The manufacturing and assembly process of a cyclone separator according to claim 1, characterized in that: Perform a water pressure test on the tube panel section in step S9.

6. The manufacturing and assembly process of a cyclone separator according to claim 1, characterized in that: In step S12, eight positioning tubes are first installed in sequence along the circumferential direction in the middle of the cylinder, and the positioning tubes are used to position two adjacent tubes in the circumferential direction. Then, a reference line is longitudinally engraved on the inner wall of the cylinder.

7. The manufacturing and assembly process of a cyclone separator according to claim 1, characterized in that: In step S12, spot welding is performed on the pipe and the sealing steel plate before welding and sealing.

8. The manufacturing and assembly process of a cyclone separator according to claim 1, characterized in that: The welding operation in step S13 adopts multi-station simultaneous welding. After the worker welds one side, he turns over and welds the other side.

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