An automated welding method for a tunnel boring machine cutter drum

Abstract

The invention relates to an automated welding method for a roller cutter barrel of a tunnel boring machine, and the invention aims to solve the problems of poor overall weld quality of manual welding and certain safety hazards in internal weld welding in the prior art. The invention comprises the following steps: 1) welding the inner annular seam between the barrel and the flange; 2) using a 180-degree angle grinder to clean the inner annular seam, polishing it to a smooth surface, performing penetrant testing, and preheating it in a trolley resistance furnace when it is free of defects, at a temperature of 250-350°C, and keeping it warm for 3-5 hours; 3) simultaneously welding the outer annular seam between the barrel and the flange, and the outer annular seam between the end face and the barrel; the automated welding adopts a rubber wheel roller for angle adjustment, and adopts an RH-06 industrial robot for welding, wherein both the inner and outer annular seams adopt a multi-layer press channel, CO2 is selected as the gas, and the gas retention is adjusted to 2.0L / min.

Description

Technical Field

[0001] The invention belongs to the technical field of tunnel boring machines, and in particular relates to an automatic welding method for a roller cutter barrel of a tunnel boring machine. Background Art

[0002] The cutter drum of a tunnel boring machine is used to mount the cutters, see Figure 1 The knife barrel is cylindrical and consists of three parts: end face, barrel and flange. The knife barrel is made of 42CrMo. Welding requirements: All welds should be 100% UT tested and meet the requirements of NB / T47013.

[0003] The knife barrel has three welds: an inner ring seam, which is the inner surface weld between the barrel and the inner surface of the flange; and two outer ring seams, which are the outer surface welds between the end face and the knife barrel, and the outer surface welds between the knife barrel and the flange. In the prior art, manual welding is used for the three welds of the knife barrel. Since the inner diameter of the knife barrel is 520mm, which is relatively large, the wall thickness after processing is 35mm, plus the wall thickness of the processing reserve is about 45mm, and the horizontal distance of the weld is 150mm. Manual welding requires reaching into the interior of the knife barrel to weld, which has poor visibility and is prone to fatigue. The welding process must be kept at a temperature of over 200 degrees, which produces a lot of smoke and dust, and there are major safety hazards. In addition, due to the large amount of knife barrel welding and the uncertainty of manual welding, welders have to work for a long time in a very harsh welding environment, making it difficult to ensure the stability of the weld. This causes uneven internal stress in the weld, resulting in defects such as weld cracks, which directly affect the welding quality. Moreover, 100% UT testing is very strict. Any slight omission will cause the test to fail, requiring repair, resulting in a waste of manpower and material resources. Summary of the Invention

[0004] The purpose of the present invention is to provide an automated welding method for a tunnel boring machine cutter drum, so as to solve the problems of poor overall weld quality of manual welding and certain safety hazards in internal weld welding in the prior art.

[0005] To achieve the above-mentioned purpose, the present invention provides an automated welding method for a tunnel boring machine cutter drum, including assembly welding of the cutter drum and automated welding of the entire drum.

[0006] The knife barrel is welded manually.

[0007] The automated welding process is:

[0008] 1) Inner annular seam welding between the cylinder and the flange;

[0009] 2) Use a 180-degree angle grinder to clean the inner annular seam. After polishing the surface to a smooth finish, perform penetrant testing. When no defects are detected, place the steel in a trolley resistance furnace for preheating at 250°C-350°C for 3-5 hours.

[0010] 3) Simultaneously weld the outer annular seam between the cylinder and the flange, and the outer annular seam between the end face and the cylinder;

[0011] The automated welding uses a rubber wheel roller for angle adjustment and an RH-06 industrial robot for welding. The inner and outer annular seams are both welded using a multi-layer press. CO2 is used as the gas and the gas retention is adjusted to 2.0L / min.

[0012] The described group welding comprises the following steps:

[0013] Step 1: Grind the weld groove and groove edge of the weldment to remove burrs and oil stains until the entire weld groove and edge are bright;

[0014] Step 2: Evenly heat the groove and groove edge of the polished workpiece to 150℃-250℃;

[0015] Step 3: Use NB-500CO2 gas shielded welding machine to manually weld the outer ring seam between the end face and the knife barrel. The current is 180A-220A, the voltage is 26V-29V, the spot welding point is 20-30mm long, and the opposite point is reinforced after 8 points in sequence. The CO2 gas flow rate is 15l / min, the reinforcement weld is 40-50mm long, the interval is 150-200mm, and reinforcement is done one by one. During reinforcement, all points on the opposite side are reinforced.

[0016] Step 4: Use asbestos cloth to wrap the weld between the end face and the cylinder after welding in step 3;

[0017] Step 5: Use NB-500CO2 gas shielded welding machine to manually weld the outer ring seam and inner ring seam between the flange and the cutter barrel. The current is 180A-220A, the voltage is 26V-29V, the spot welding point is 20-30mm long, and the opposite point is reinforced after 8 points in sequence. The CO2 gas flow rate is 15l / min, the reinforcement weld is 40-50mm long, the interval is 150-200mm, and reinforcement is carried out step by step. During reinforcement, all points on the opposite side are reinforced.

[0018] Step 6: Send the knife barrel welded in step 5 into the trolley resistance furnace for heating and prepare for robot automated welding.

[0019] The grinding described in step 1 is performed using a Φ125 angle grinder, and the grinding position is 20-30 mm from the weld groove and the edge of the groove.

[0020] The heating in step 2 is to uniformly heat the workpiece groove and the groove edge 50-150mm using oxygen and acetylene flames.

[0021] The knife barrel described in step 3 is sent into a trolley resistance furnace for heating. When the preheating temperature reaches 350°C, insulation is started for 3-4 hours.

[0022] When the automated welding uses a rubber wheel roller for angle adjustment, the angle between the roller and the center of the knife barrel is 30°-40°, the outer diameter of the knife barrel is 640mm, and the center distance of the roller is adjusted to 320mm-450mm.

[0023] The inner annular seam welding process between the cylinder and the flange comprises the following steps:

[0024] Step 1: Weld the first layer of weld seam. The nozzle is fixed at a 15° horizontal angle to the center of the weld seam at the bottom of the inner wall of the cutter barrel, and the longitudinal direction is at the center of the weld seam. The current is 200A-260A, the voltage is 25V-30V, the tire speed is 300-350mm / min, and the direction of rotation of the cutter barrel is counterclockwise. During the welding process, the outer wall of the cutter barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0025] Step 2: Perform the second layer of welding on the weld, with the nozzle position unchanged and performing Z-shaped swing, the frequency is 1.5Hz-3.0Hz, the swing amplitude is 2.5mm-4.0mm, the dwell time is 0.4S, the knife barrel speed is 300-350mm / min, the current is 200A-260A, the voltage is 25V-30V, and the knife barrel rotates counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames, the oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃;

[0026] Step 3: Perform the third layer of Z-shaped nozzle swing on the weld seam, with a frequency of 1.8Hz-2.5Hz, a swing amplitude of 6.0mm-8.0mm, a dwell time of 0.5S, a knife barrel speed of 300-350mm / min, a current of 200A-260A, a voltage of 25V-30V, and a knife barrel rotation direction of counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0027] Step 4: Perform welding of the fourth to sixth layers of the weld seam, with the nozzle swinging in a Z shape, a frequency of 1.8Hz-2.5Hz, an amplitude of 6.0mm-8.0mm, a dwell time of 0.5S, a knife barrel speed of 200-250mm / min, a current of 200A-260A, a voltage of 25V-30V, and a counterclockwise rotation direction of the knife barrel. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0028] Step 5: Perform welding on the seventh to ninth layers of the weld seam, with the nozzle swinging in Z shape, the frequency being 1.5Hz-2.0Hz, the swing amplitude being 8.5mm-9.5mm, the dwell time being 0.7S, the knife barrel speed being 150-200mm / min, the current being 200A-260A, the voltage being 25V-30V, and the knife barrel rotating direction being counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames, the oxygen flow rate being controlled at 0.4-0.6MPa, the acetylene flow rate being controlled at 0.05-0.07MPa, and the temperature being controlled between 180℃-300℃.

[0029] Step 6: Perform the tenth layer of welding on the weld, with the gun nozzle swinging in Z shape, the frequency of 1.5Hz-2.0Hz, the swing amplitude of 8.5mm-9.5mm, the swing amplitude of 8.5mm-9.5mm, the dwell time of 0.7S, the knife barrel rotates clockwise, the speed of 80-100mm / min, the current of 200A-260A, and the voltage of 25V-30V. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0030] The outer ring seam welding between the shell and the flange includes the following steps:

[0031] Step 1: Perform the first layer of welding on the weld, fix the nozzle, rotate the knife barrel counterclockwise at 300-350mm / min, current 200A-260A, voltage 25V-30V;

[0032] Step 2: Repeat step 1) to weld the second layer of weld seam;

[0033] Step 3: Perform the third layer of welding on the weld, with the nozzle swinging in a Z shape, a frequency of 1.5Hz-3.0Hz, a swing amplitude of 3.0mm-5.0mm, a retention time of 0.4s, and the knife barrel rotating counterclockwise at 300-350mm / min;

[0034] Step 4: Perform the fourth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.8Hz-2.5Hz, swing amplitude 5.0mm-8.0mm, retention time 0.5S, and knife barrel speed 200-250mm / min;

[0035] Step 5: Perform the fifth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min;

[0036] Step 6: Perform the sixth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min.

[0037] Step 7: Repeat step 5) to weld the seventh and eighth layers of the weld in sequence, with the drum speed at 150-200 mm / min;

[0038] Step 8: Repeat step 6) to weld the ninth layer of the weld, wherein the knife drum speed is 150-200 mm / min;

[0039] Step 9: Repeat step 5) to weld the tenth layer of weld seam, wherein the knife barrel rotates clockwise at a speed of 80-100 mm / min;

[0040] Step 10: Use oxygen and acetylene flames to heat the edge of the weld by 50mm-100mm, and adopt gradient heating. First heat to 100℃ and keep warm for 1 hour, then heat to 200℃ and keep warm for 1 hour, and finally heat to 300℃ and keep warm for 2 hours. Then put it into a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, keep warm for 2-3 hours, and then cool it.

[0041] The outer girth welding between the end face and the cylinder includes the following steps:

[0042] Step 1: Perform the first layer of welding on the weld, fix the nozzle, angle 15°-30°, rotate the knife barrel counterclockwise at 300-350mm / min, current 200A-260A, voltage 25V-30V;

[0043] Step 2: Repeat step 1) to weld the second layer of weld seam;

[0044] Step 3: Perform the third layer of welding on the weld, with the nozzle swinging in a Z shape, a frequency of 1.5Hz-3.0Hz, a swing amplitude of 3.0mm-5.0mm, a retention time of 0.4s, and the knife barrel rotating counterclockwise at 300-350mm / min;

[0045] Step 4: Perform the fourth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.8Hz-2.5Hz, swing amplitude 5.0mm-8.0mm, retention time 0.5S, knife barrel speed 200-250mm / min, nozzle angle 20°-40°;

[0046] Step 5: Perform the fifth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min;

[0047] Step 6: Perform the sixth layer of welding on the weld, with the nozzle swinging in Z shape, the angle of 30°-50°, the frequency of 1.5Hz-2.0Hz, the swing amplitude of 8.5mm-9.5mm, the retention time of 0.7S, and the knife barrel speed of 200-250mm / min.

[0048] Step 7: Repeat step 5) to weld the seventh and eighth layers of the weld in sequence, with the drum speed at 150-200 mm / min;

[0049] Step 8: Repeat step 6) to weld the ninth layer of the weld, wherein the knife drum speed is 150-200 mm / min;

[0050] Step 9: Repeat step 5) to weld the tenth layer of weld seam, wherein the knife barrel rotates clockwise at a speed of 80-100 mm / min;

[0051] Step 10: Use oxygen and acetylene flames to heat the edge of the weld by 50mm-100mm, and adopt gradient heating. First heat to 100℃ and keep warm for 1 hour, then heat to 200℃ and keep warm for 1 hour, and finally heat to 300℃ and keep warm for 2 hours. Then put it into a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, keep warm for 2-3 hours, and then cool it.

[0052] An automated welding method for a tunnel boring machine cutter drum, characterized by comprising assembly welding of the cutter drum and automated welding of the entire drum;

[0053] The knife barrel is welded manually.

[0054] The automated welding process is:

[0055] 1) Inner annular seam welding between the cylinder and the flange;

[0056] 2) Use a 180-degree angle grinder to clean the inner annular seam. After polishing the surface to a smooth finish, perform penetrant testing. When no defects are detected, place the steel in a trolley resistance furnace for preheating at 250°C-350°C for 3-5 hours.

[0057] 3) Weld the outer annular seam between the cylinder and the flange;

[0058] 4) Weld the outer annular seam between the end face and the cylinder;

[0059] The automated welding uses a rubber wheel roller for angle adjustment and an RH-06 industrial robot for welding. The inner and outer annular seams are both welded using a multi-layer press. The gas used is CO2, and the gas retention rate is adjusted to 2.0L / min.

[0060] The present invention provides the following beneficial effects: The automated welding method for the cutter drum of a tunnel boring machine employs robotic welding, effectively preventing direct contact between operators and the cutter drum. Welding fumes are kept at a distance from operators, ensuring essential safety. Robotic welding offers high precision and stability, preventing oversights caused by prolonged operation and effectively ensuring weld quality. Robotic welding allows one person to perform multiple operations, effectively saving human resources and increasing production efficiency by more than three times. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 This is a schematic diagram of the cutter drum structure of a tunnel boring machine;

[0062] Figure 2 Schematic diagram of the weld structure between the cylinder and the flange;

[0063] Figure 3 This is an enlarged view of the weld between the cylinder and the flange;

[0064] Figure 4 Schematic diagram of the weld structure between the end face and the cylinder;

[0065] Among them: 1. End face, 2. Cylinder, 3. Flange. DETAILED DESCRIPTION

[0066] The embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0067] Example 1

[0068] The present invention provides an automated welding method for a tunnel boring machine cutter drum, including assembly welding of the cutter drum and automated welding of the entire drum.

[0069] The knife barrel is welded manually.

[0070] The automated welding process is:

[0071] 1) Inner annular seam welding between the cylinder and the flange;

[0072] 2) Use a 180-degree angle grinder to clean the inner annular seam. After polishing the surface to a smooth finish, perform penetrant testing. When no defects are detected, place the steel in a trolley resistance furnace for preheating at 250°C-350°C for 3-5 hours.

[0073] 3) Simultaneously weld the outer annular seam between the cylinder and the flange, and the outer annular seam between the end face and the cylinder;

[0074] The automated welding uses a rubber wheel roller for angle adjustment and an RH-06 industrial robot for welding. The inner and outer annular seams are both welded using a multi-layer press. CO2 is used as the gas and the gas retention is adjusted to 2.0L / min.

[0075] The equipment required for the automatic welding of the hob cutter barrel of the present invention includes:

[0076] Robotic welding equipment: RH-06 industrial robot, fully digital IGBT inverter CO2 / MAG multifunctional welding machine, industrial robot voltage regulator;

[0077] Rubber wheel roller: a device that assists the knife barrel welding. The arc surface of the knife barrel is placed on the rubber wheel roller, and the knife barrel is in the welding process;

[0078] Trolley furnace;

[0079] Oxygen and acetylene heating tools;

[0080] Φ125, Φ180 angle grinders and sandpaper and grinding wheels;

[0081] Straight twelve-pin pneumatic rust removal hammer;

[0082] THY-51B flux-cored Φ1.2 welding wire;

[0083] 8.5mm thick asbestos cloth;

[0084] Temperature gun;

[0085] CO2 cylinders;

[0086] NB-500CO2 gas shielded welding machine.

[0087] The described group welding comprises the following steps:

[0088] Step 1: Grind the weld groove and groove edge of the weldment to remove burrs and oil stains until the entire weld groove and edge are bright;

[0089] Step 2: Evenly heat the groove and groove edge of the polished workpiece to 150℃-250℃;

[0090] Step 3: Use NB-500CO2 gas shielded welding machine to manually weld the outer ring seam between end face 1 and the knife barrel. The current is 180A-220A, the voltage is 26V-29V, the spot welding point length is 20-30mm, and the opposite point is reinforced after 8 points in sequence. The CO2 gas flow rate is 15l / min, the reinforcement weld is 40-50mm long, the interval is 150-200mm, and reinforcement is performed successively. During reinforcement, all points on the opposite side are reinforced.

[0091] Step 4: Wrap the weld between the end face 1 and the cylinder 2 after the welding in step 3 with asbestos cloth to prevent cracks caused by rapid cooling;

[0092] Step 5: Use NB-500CO2 gas shielded welding machine to manually weld the outer ring seam and then the inner ring seam between flange 3 and knife barrel. The current is 180A-220A, the voltage is 26V-29V, the spot welding point length is 20-30mm, and the opposite point is reinforced after 8 points in sequence. The CO2 gas flow rate is 15l / min, the reinforcement weld is 40-50mm long, the interval is 150-200mm, and reinforcement is performed successively. During reinforcement, all points on the opposite side are reinforced.

[0093] Step 6: Send the knife barrel welded in step 5 into the trolley resistance furnace for heating and prepare for robot automated welding.

[0094] The grinding described in step 1 is performed using a Φ125 angle grinder, and the grinding position is 20-30 mm from the weld groove and the edge of the groove.

[0095] The heating in step 2 is to uniformly heat the workpiece groove and the groove edge 50-150mm using oxygen and acetylene flames.

[0096] The knife barrel described in step 3 is sent to the trolley resistance furnace for heating. When the preheating temperature reaches 350°C, insulation begins. In order to prevent the heat from dissipating too quickly during welding and to prevent internal stress, the insulation time is 3-4 hours.

[0097] When the automated welding uses a rubber wheel roller for angle adjustment, the angle between the roller and the center of the knife barrel is 30°-40°, the outer diameter of the knife barrel is 640mm, and the center distance of the roller is adjusted to 320mm-450mm.

[0098] The inner annular seam welding process between the cylinder 2 and the flange 3 includes the following steps:

[0099] Step 1: Weld the first layer of weld seam. The nozzle is fixed at a 15° horizontal angle to the center of the weld seam at the bottom of the inner wall of the cutter barrel, and the longitudinal direction is at the center of the weld seam. The current is 200A-260A, the voltage is 25V-30V, the tire speed is 300-350mm / min, and the direction of rotation of the cutter barrel is counterclockwise. During the welding process, the outer wall of the cutter barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0100] Step 2: Perform the second layer of welding on the weld, with the nozzle position unchanged and performing Z-shaped swing, the frequency is 1.5Hz-3.0Hz, the swing amplitude is 2.5mm-4.0mm, the dwell time is 0.4S, the knife barrel speed is 300-350mm / min, the current is 200A-260A, the voltage is 25V-30V, and the knife barrel rotates counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames, the oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃;

[0101] Step 3: Perform the third layer of Z-shaped nozzle swing on the weld seam, with a frequency of 1.8Hz-2.5Hz, a swing amplitude of 6.0mm-8.0mm, a dwell time of 0.5S, a knife barrel speed of 300-350mm / min, a current of 200A-260A, a voltage of 25V-30V, and a knife barrel rotation direction of counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0102] Step 4: Perform welding of the fourth to sixth layers of the weld seam, with the nozzle swinging in a Z shape, a frequency of 1.8Hz-2.5Hz, an amplitude of 6.0mm-8.0mm, a dwell time of 0.5S, a knife barrel speed of 200-250mm / min, a current of 200A-260A, a voltage of 25V-30V, and a counterclockwise rotation direction of the knife barrel. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0103] Step 5: Perform welding on the seventh to ninth layers of the weld seam, with the nozzle swinging in Z shape, the frequency being 1.5Hz-2.0Hz, the swing amplitude being 8.5mm-9.5mm, the dwell time being 0.7S, the knife barrel speed being 150-200mm / min, the current being 200A-260A, the voltage being 25V-30V, and the knife barrel rotating direction being counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames, the oxygen flow rate being controlled at 0.4-0.6MPa, the acetylene flow rate being controlled at 0.05-0.07MPa, and the temperature being controlled between 180℃-300℃.

[0104] Step 6: Perform the tenth layer of welding on the weld, with the gun nozzle swinging in Z shape, the frequency of 1.5Hz-2.0Hz, the swing amplitude of 8.5mm-9.5mm, the swing amplitude of 8.5mm-9.5mm, the dwell time of 0.7S, the knife barrel rotates clockwise, the speed of 80-100mm / min, the current of 200A-260A, and the voltage of 25V-30V. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

[0105] The outer annular seam welding between the cylinder 2 and the flange 3 includes the following steps:

[0106] Step 1: Perform the first layer of welding on the weld, fix the nozzle, rotate the knife barrel counterclockwise at 300-350mm / min, current 200A-260A, voltage 25V-30V;

[0107] Step 2: Repeat step 1) to weld the second layer of weld seam;

[0108] Step 3: Perform the third layer of welding on the weld, with the nozzle swinging in a Z shape, a frequency of 1.5Hz-3.0Hz, a swing amplitude of 3.0mm-5.0mm, a retention time of 0.4s, and the knife barrel rotating counterclockwise at 300-350mm / min;

[0109] Step 4: Perform the fourth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.8Hz-2.5Hz, swing amplitude 5.0mm-8.0mm, retention time 0.5S, and knife barrel speed 200-250mm / min;

[0110] Step 5: Perform the fifth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min;

[0111] Step 6: Perform the sixth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min.

[0112] Step 7: Repeat step 5) to weld the seventh and eighth layers of the weld in sequence, with the drum speed at 150-200 mm / min;

[0113] Step 8: Repeat step 6) to weld the ninth layer of the weld, wherein the knife drum speed is 150-200 mm / min;

[0114] Step 9: Repeat step 5) to weld the tenth layer of weld seam, wherein the knife barrel rotates clockwise at a speed of 80-100 mm / min;

[0115] Step 10: Use oxygen and acetylene flames to heat the edge of the weld by 50mm-100mm, and adopt gradient heating. First heat to 100℃ and keep warm for 1 hour, then heat to 200℃ and keep warm for 1 hour, and finally heat to 300℃ and keep warm for 2 hours. Then put it into a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, keep warm for 2-3 hours, and then cool it.

[0116] The outer annular seam welding between the end face 1 and the cylinder 2 includes the following steps:

[0117] Step 1: Perform the first layer of welding on the weld, fix the nozzle, angle 15°-30°, rotate the knife barrel counterclockwise at 300-350mm / min, current 200A-260A, voltage 25V-30V;

[0118] Step 2: Repeat step 1) to weld the second layer of weld seam;

[0119] Step 3: Perform the third layer of welding on the weld, with the nozzle swinging in a Z shape, a frequency of 1.5Hz-3.0Hz, a swing amplitude of 3.0mm-5.0mm, a retention time of 0.4s, and the knife barrel rotating counterclockwise at 300-350mm / min;

[0120] Step 4: Perform the fourth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.8Hz-2.5Hz, swing amplitude 5.0mm-8.0mm, retention time 0.5S, knife barrel speed 200-250mm / min, nozzle angle 20°-40°;

[0121] Step 5: Perform the fifth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min;

[0122] Step 6: Perform the sixth layer of welding on the weld, with the nozzle swinging in Z shape, the angle of 30°-50°, the frequency of 1.5Hz-2.0Hz, the swing amplitude of 8.5mm-9.5mm, the retention time of 0.7S, and the knife barrel speed of 200-250mm / min.

[0123] Step 7: Repeat step 5) to weld the seventh and eighth layers of the weld in sequence, with the drum speed at 150-200 mm / min;

[0124] Step 8: Repeat step 6) to weld the ninth layer of the weld, wherein the knife drum speed is 150-200 mm / min;

[0125] Step 9: Repeat step 5) to weld the tenth layer of weld seam, wherein the knife barrel rotates clockwise at a speed of 80-100 mm / min;

[0126] Step 10: Use oxygen and acetylene flames to heat the edge of the weld 50mm-100mm, and adopt gradient heating. First heat to 100℃ and keep warm for 1 hour, then heat to 200℃ and keep warm for 1 hour, and finally heat to 300℃ and keep warm for 2 hours. Then put it into a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, keep warm for 2-3 hours, and then cool it.

[0127] The rubber wheel rotates counterclockwise, which offers the advantages of good weld fusion and high weld strength. During welding, the wheel speed is 300-350 mm / min for layers 1-3, 200-250 mm / min for layers 4-6, and 150-200 mm / min for layers 7-9. The 10th layer rotates clockwise at 80-100 mm / min, ensuring a well-formed, aesthetically pleasing weld. Argon gas is continuously inflated throughout the welding process to prevent the release of harmful elements such as sulfur and phosphorus.

[0128] See also Figure 2 and Figure 3 As the wall thickness of the knife barrel is about 45mm, multi-layer pressure welding is adopted. The RH-06 industrial robot is used for automated welding, and the gas is CO2 with a gas flow rate of 2.0L / min.

[0129] See also Figure 4 In the welding process, a self-made multi-head baking gun is used. In this embodiment, an eight-head baking gun is used. The eight baking guns can evenly heat the inside and outside of the knife barrel, ensuring a uniform heating process and a smoother welding process.

[0130] Install a pneumatic slag hammer inside the cutter barrel at a distance of 200mm-300mm from the welding gun. During welding, use the pneumatic slag hammer to remove slag and continuously and evenly relieve stress. Hammer the weld and the weld 20-40mm away with the slag hammer until all welds are hammered.

[0131] After all welds are completed, use oxygen and acetylene flames to heat the welds and the edges 50mm-100mm for dehydrogenation treatment. The temperature is heated in a gradient manner, first heated to 100℃ and kept warm for 1 hour, then heated to 200℃ and kept warm for 1 hour, and finally heated to 300℃ and kept warm for 2 hours, then placed in a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, kept warm for 2-3 hours and then ring cooled.

[0132] Two robots are used to weld the outer annular seam at the joint of the flange 3 and the cylinder 2, and the outer annular seam at the joint of the end face 1 and the cylinder 2 simultaneously. Although the depth, width and groove of the two welds are completely different, by adjusting the current, voltage, welding gun swing speed and other parameters of the two welding robots, the outer annular seams of the two places can be welded at the same speed with one rotation of the knife barrel, and the welding tasks at both places can be completed simultaneously.

[0133] Example 1

[0134] The difference between this embodiment and the first embodiment is that the outer annular seam between the cylinder 2 and the flange 3 and the outer annular seam between the cylinder 2 and the end face 1 are welded successively; specifically:

[0135] An automated welding method for a tunnel boring machine cutter drum, characterized by comprising assembly welding of the cutter drum and automated welding of the entire drum;

[0136] The knife barrel is welded manually.

[0137] The automated welding process is:

[0138] 1) Inner annular seam welding between the cylinder 2 and the flange 3;

[0139] 2) Use a 180-degree angle grinder to clean the inner annular seam. After polishing the surface to a smooth finish, perform penetrant testing. When no defects are detected, place the steel in a trolley resistance furnace for preheating at 250°C-350°C for 3-5 hours.

[0140] 3) Welding the outer annular seam between the cylinder 2 and the flange 3;

[0141] 4) Welding the outer annular seam between the end face 1 and the cylinder 2;

[0142] The automated welding uses a rubber wheel roller for angle adjustment and an RH-06 industrial robot for welding. The inner and outer annular seams are both welded using a multi-layer press. The gas used is CO2, and the gas retention rate is adjusted to 2.0L / min.

[0143] In this embodiment, the welding process of the inner annular seam and each outer annular seam is the same as that of the first embodiment.

Claims

1. An automated welding method for a tunnel boring machine cutter drum, characterized in that: Including the assembly welding of the knife barrel and the overall automated welding; The knife barrel is welded manually. The automated welding process is: 1) Inner annular seam welding between the cylinder (2) and the flange (3); 2) Use a 180-degree angle grinder to clean the inner annular seam. After polishing the surface to a smooth finish, perform penetrant testing. When no defects are detected, place the steel in a trolley resistance furnace for preheating at 250°C-350°C for 3-5 hours. 3) Simultaneously welding the outer annular seam between the cylinder (2) and the flange (3) and the outer annular seam between the end face (1) and the cylinder (2); The automated welding uses rubber wheel rollers for angle adjustment and RH-06 industrial robots for welding. The inner and outer annular seams are welded using multi-layer presses. CO2 is used as the gas, and the gas flow rate is adjusted to 2.0L / min. The inner annular seam welding process between the cylinder (2) and the flange (3) comprises the following steps: Step 1: Weld the first layer of weld seam. The nozzle is fixed at a 15° horizontal angle to the center of the weld seam at the bottom of the inner wall of the cutter barrel, and the longitudinal direction is at the center of the weld seam. The current is 200A-260A, the voltage is 25V-30V, the tire speed is 300-350mm / min, and the direction of rotation of the cutter barrel is counterclockwise. During the welding process, the outer wall of the cutter barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃. Step 2: Perform the second layer of welding on the weld, with the nozzle position unchanged and performing Z-shaped swing, the frequency is 1.5Hz-3.0Hz, the swing amplitude is 2.5mm-4.0mm, the dwell time is 0.4S, the knife barrel speed is 300-350mm / min, the current is 200A-260A, the voltage is 25V-30V, and the knife barrel rotates counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames, the oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃; Step 3: Perform the third layer of Z-shaped nozzle swing on the weld seam, with a frequency of 1.8Hz-2.5Hz, a swing amplitude of 6.0mm-8.0mm, a dwell time of 0.5S, a knife barrel speed of 300-350mm / min, a current of 200A-260A, a voltage of 25V-30V, and a knife barrel rotation direction of counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃. Step 4: Perform welding of the fourth to sixth layers of the weld seam, with the nozzle swinging in a Z shape, a frequency of 1.8Hz-2.5Hz, an amplitude of 6.0mm-8.0mm, a dwell time of 0.5S, a knife barrel speed of 200-250mm / min, a current of 200A-260A, a voltage of 25V-30V, and a counterclockwise rotation direction of the knife barrel. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃. Step 5: Perform welding on the seventh to ninth layers of the weld seam, with the nozzle swinging in Z shape, the frequency being 1.5Hz-2.0Hz, the swing amplitude being 8.5mm-9.5mm, the dwell time being 0.7S, the knife barrel speed being 150-200mm / min, the current being 200A-260A, the voltage being 25V-30V, and the knife barrel rotating direction being counterclockwise. During the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames, the oxygen flow rate being controlled at 0.4-0.6MPa, the acetylene flow rate being controlled at 0.05-0.07MPa, and the temperature being controlled between 180℃-300℃. Step 6: Perform the tenth layer of welding on the weld, with the nozzle swinging in Z shape, the frequency of 1.5Hz-2.0Hz, the swing amplitude of 8.5mm-9.5mm, the dwell time of 0.7S, the knife barrel changing to clockwise rotation, the speed of 80-100mm / min, the current of 200A-260A, the voltage of 25V-30V, and during the welding process, the outer wall of the knife barrel is evenly heated with oxygen and acetylene flames. The oxygen flow rate is controlled at 0.4-0.6MPa, the acetylene flow rate is controlled at 0.05-0.07MPa, and the temperature is controlled between 180℃-300℃.

2. The automated welding method for a tunnel boring machine cutter drum according to claim 1, characterized in that: The described group welding comprises the following steps: Step 1: Grind the weld groove and groove edge of the weldment to remove burrs and oil stains until the entire weld groove and edge are bright; Step 2: Evenly heat the groove and groove edge of the polished workpiece to 150℃-250℃; Step 3: Use NB-500 CO2 gas shielded welding machine to manually weld the outer ring seam between the end face (1) and the knife barrel, the current is 180A-220A, the voltage is 26V-29V, the spot welding point length is 20-30mm, and the opposite point welding is successively reinforced after 8 points, the CO2 gas flow rate is 15l / min, the reinforcement welding bead length is 40-50mm, the interval is 150-200mm, and the reinforcement is carried out successively, and the opposite point reinforcement is always carried out; Step 4: Wrap the weld bead between the end face (1) and the cylinder (2) after the welding in step 3 with asbestos cloth; Step 5: Use NB-500 CO2 gas shielded welding machine to manually weld the outer annular seam and then the inner annular seam between the flange (3) and the knife barrel, the current is 180A-220A, the voltage is 26V-29V, the spot welding point length is 20-30mm, and the opposite point welding is successively strengthened at 8 points and then reinforced, the CO2 gas flow rate is 15l / min, the reinforcement welding bead length is 40-50mm, the interval is 150-200mm, and reinforcement is performed successively, and the opposite point reinforcement is performed; Step 6: Send the knife barrel welded in step 5 into the trolley resistance furnace for heating and prepare for robot automated welding.

3. The automated welding method for a tunnel boring machine cutter drum according to claim 2, characterized in that: The grinding described in step 1 is performed using a Φ125 angle grinder, and the grinding position is 20-30 mm from the weld groove and the edge of the groove.

4. The automated welding method for a tunnel boring machine cutter drum according to claim 2, characterized in that: The heating in step 2 is to uniformly heat the workpiece groove and the groove edge 50-150mm using oxygen and acetylene flames.

5. The automated welding method for a tunnel boring machine cutter drum according to claim 2, characterized in that: The knife barrel described in step 3 is sent into a trolley resistance furnace for heating. When the preheating temperature reaches 350°C, insulation is started for 3-4 hours.

6. The automated welding method for a tunnel boring machine cutter drum according to claim 1, characterized in that: When the automated welding uses a rubber wheel roller for angle adjustment, the angle between the roller and the center of the knife barrel is 30°-40°, the outer diameter of the knife barrel is 640mm, and the center distance of the roller is adjusted to 320mm-450mm.

7. The automated welding method for a tunnel boring machine cutter drum according to claim 1, characterized in that: The outer annular seam welding between the cylinder (2) and the flange (3) comprises the following steps: Step 1: Perform the first layer of welding on the weld, fix the nozzle, rotate the knife barrel counterclockwise at 300-350mm / min, current 200A-260A, voltage 25V-30V; Step 2: Repeat step 1) to weld the second layer of weld seam; Step 3: Perform the third layer of welding on the weld, with the nozzle swinging in a Z shape, a frequency of 1.5Hz-3.0Hz, a swing amplitude of 3.0mm-5.0mm, a retention time of 0.4s, and the knife barrel rotating counterclockwise at 300-350mm / min; Step 4: Perform the fourth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.8Hz-2.5Hz, swing amplitude 5.0mm-8.0mm, retention time 0.5S, and knife barrel speed 200-250mm / min; Step 5: Perform the fifth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min; Step 6: Perform the sixth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min; Step 7: Repeat step 5) to weld the seventh and eighth layers of the weld in sequence, with the drum speed at 150-200 mm / min; Step 8: Repeat step 6) to weld the ninth layer of the weld, wherein the knife drum speed is 150-200 mm / min; Step 9: Repeat step 5) to weld the tenth layer of weld seam, wherein the knife barrel rotates clockwise at a speed of 80-100 mm / min; Step 10: Use oxygen and acetylene flames to heat the edge of the weld 50mm-100mm, and adopt gradient heating. First heat to 100℃ and keep warm for 1 hour, then heat to 200℃ and keep warm for 1 hour, and finally heat to 300℃ and keep warm for 2 hours. Then put it into a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, keep warm for 2-3 hours, and then cool it.

8. The automated welding method for a tunnel boring machine cutter drum according to claim 1, characterized in that: The outer annular seam welding between the end face (1) and the cylinder (2) comprises the following steps: Step 1: Perform the first layer of welding on the weld, fix the nozzle, angle 15°-30°, rotate the knife barrel counterclockwise at 300-350mm / min, current 200A-260A, voltage 25V-30V; Step 2: Repeat step 1) to weld the second layer of weld seam; Step 3: Perform the third layer of welding on the weld, with the nozzle swinging in a Z shape, a frequency of 1.5Hz-3.0Hz, a swing amplitude of 3.0mm-5.0mm, a retention time of 0.4s, and the knife barrel rotating counterclockwise at 300-350mm / min; Step 4: Perform the fourth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.8Hz-2.5Hz, swing amplitude 5.0mm-8.0mm, retention time 0.5S, knife barrel speed 200-250mm / min, nozzle angle 20°-40°; Step 5: Perform the fifth layer of welding on the weld, with the nozzle swinging in Z shape, frequency 1.5Hz-2.0Hz, swing amplitude 8.5mm-9.5mm, retention time 0.7S, and knife barrel speed 200-250mm / min; Step 6: Perform the sixth layer of welding on the weld, with the nozzle swinging in a Z shape, an angle of 30°-50°, a frequency of 1.5Hz-2.0Hz, a swing amplitude of 8.5mm-9.5mm, a retention time of 0.7S, and a knife barrel speed of 200-250mm / min; Step 7: Repeat step 5) to weld the seventh and eighth layers of the weld in sequence, with the drum speed at 150-200 mm / min; Step 8: Repeat step 6) to weld the ninth layer of the weld, wherein the knife drum speed is 150-200 mm / min; Step 9: Repeat step 5) to weld the tenth layer of weld seam, wherein the knife barrel rotates clockwise at a speed of 80-100 mm / min; Step 10: Use oxygen and acetylene flames to heat the edge of the weld 50mm-100mm, and adopt gradient heating. First heat to 100℃ and keep warm for 1 hour, then heat to 200℃ and keep warm for 1 hour, and finally heat to 300℃ and keep warm for 2 hours. Then put it into a desktop resistance furnace for ring cooling. The trolley resistance furnace is 250℃-350℃, keep warm for 2-3 hours, and then cool it.

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