A manual welding method for loader bucket structure

Abstract

A method for manually making and welding a loader bucket structure, wherein the loader bucket structure includes a loader bucket body, with a left blade and a right blade respectively welded on both sides of the body, the loader bucket body being concave inward to form a structure with a large arc-shaped back, and a reinforcing bent plate being provided above and below the arc-shaped structure, wherein a small bent plate is welded to the left and right blades in front of the upper reinforcing bent plate, an inner reinforcing bent plate is welded below the small bent plate, a bottom plate parallel to the ground is welded in front of the lower reinforcing bent plate, a main blade is arranged in front of the bottom plate, and two upper rib plates arranged in a mirror image are welded to the upper reinforcing bent plate, and at least one ear plate assembly and an intermediate plate assembly are arranged between the upper and lower reinforcing bent plates, and a limiting pad is arranged above the ear plate assembly.

Description

Technical Field

[0001] The invention relates to a manual manufacturing and welding method for a loader bucket structure, which is used for manual manufacturing of a large-scale structural component loader bucket and belongs to the technical field of loader bucket production and assembly. Background Art

[0002] The working parts of construction machinery such as loaders are wearing parts. After the loader has been working for several years, the working part bucket needs to be replaced due to severe wear. However, large parts like this are not easy to buy on the market, and manufacturers update their products very quickly. The best source is to customize them from manufacturers specializing in the production of buckets. However, due to the small demand, the sporadic production and assembly of buckets can only be done by manual welding. It is impossible to have professional tooling, molds and equipment for assembly line production. How to make the produced bucket match the original loader depends on a special welding production process. For this reason, a manual welding method for the loader bucket structure is designed to overcome the above problems. Summary of the Invention

[0003] The purpose of the present invention is to provide a manual manufacturing and welding method for a loader bucket structure with simple structure, small welding deformation, accurate installation position, low use cost and good production effect.

[0004] The present invention is achieved through the following technical solutions: a loader bucket structure, which includes a loader bucket body, with a left blade and a right blade respectively welded on both sides of the body, the loader bucket body is concave inward to form a large arc-shaped structure on the back, and a reinforcing bent plate is arranged above and below the arc structure, wherein a small bent plate is welded to the left and right blades in front of the upper reinforcing bent plate, an inner reinforcing bent plate is welded below the small bent plate, a bottom plate parallel to the ground is welded in front of the lower reinforcing bent plate, a main blade is arranged in front of the bottom plate, and two upper rib plates arranged in a mirror image are welded on the upper reinforcing bent plate, and at least one ear plate assembly and an intermediate plate assembly are arranged between the upper and lower reinforcing bent plates, and a limiting pad is arranged above the ear plate assembly.

[0005] Preferably: there are two ear plate assemblies, which are respectively installed on the left and right sides of the middle plate assembly and are separated from the middle plate assembly by a certain distance. Each ear plate assembly is composed of two ear plates with through holes, which are connected by a central sealing plate in the middle. The upper part is fixed to an ear plate reinforcement plate, and the lower part is fixed to the inner sealing plate. The rear end sealing plates are respectively installed on the left and right sides of the inner sealing plate, and a limiting pad is fixed above each ear plate reinforcement plate, and a first shaft sleeve is welded in the through hole.

[0006] Preferably, the intermediate plate assembly is composed of two center plates with through holes, the upper part of the center plate is fixed on the center cover plate, and the lower part is fixed on the center lower plate. A plurality of center ribs are arranged below the center cover plate to increase its strength, and a plurality of center outer ribs are arranged on the outer side of the center plate, and a second sleeve is welded in the through hole.

[0007] As a preference, the upper rib plate is provided with hanging holes for facilitating lifting, and the upper rib plate is arranged in an eight-shaped structure.

[0008] Preferably, at least one reinforcing plate is welded to the left blade and the right blade.

[0009] A manual welding method for the loader bucket structure, comprising the following steps:

[0010] 1) Cutting;

[0011] 2) Grinding and deburring;

[0012] 3) Leveling;

[0013] 4) Bending, rounding or metal processing;

[0014] 5) Each component is manually assembled and welded;

[0015] 6) Assembly points;

[0016] 7) Add a grid-mounted support frame to the bucket cavity;

[0017] 8) Add welding strips to the parts prone to deformation;

[0018] 9) Weld the bucket as a whole;

[0019] 10) Cooling;

[0020] 11) Calibration;

[0021] 12) Use simple tooling to assemble three sets of bushings;

[0022] 13) Test the three sets of assembled bushings;

[0023] 14) Through the core rod, welding is done with simple tooling;

[0024] 15) Detect three sets of hole sizes;

[0025] 16) Grind the entire surface to remove burrs and spatter;

[0026] 17) Overall shot blasting;

[0027] 18) Integral assembly of loader bucket and side teeth;

[0028] 20) Overall paint;

[0029] 21) Storage.

[0030] As a preference: the specific method of steps 1-6 is:

[0031] The whole piece of plate is bent by a bending machine, and the bent plate has a rough shape. Then it is further processed by grinding to remove burrs, leveling, bending, rounding, etc., and other small parts are processed as hardware. Small parts are first welded and assembled, such as the left and right blades, as well as the limit pads, ear plates, and center plates. Then the overall structure is roughly connected by spot welding to form a bucket.

[0032] As a preference: the specific method of steps 7-11 is: a grid-shaped support frame is installed on the inner side of the arc of the general shape after spot welding to prevent deformation, and tie rods are spot welded on the top and bottom. After installation, the entire bucket is welded as a whole, including the limit pad, ear plate, and center plate, and cooled and corrected after welding.

[0033] As a preference: the specific method of steps 12-21 is: after the installation is completed, install the shaft sleeves in the ear plate and the center plate, first spot-assemble the shaft sleeves, and then inspect them after spot-assembling, and then insert a core rod into the through holes of the ear plate and the center plate on both sides, wherein the core rod in the center plate is at the top, and the core rods of the ear plates on both sides are at the bottom, after the core rod on the center plate and the core rod between the ear plates on both sides are fixed horizontally through simple tooling, insert the shaft sleeves on the core rods and weld them simultaneously, and finally check whether the size of the hole meets the standard, and finally polish the whole to remove burrs and spatter; shot blast the whole; assemble the loader bucket and side teeth as a whole; paint the whole; and put into storage.

[0034] In the manual production of loader buckets, without the availability of tooling, molds, or equipment, the manufacturing process was reviewed and explored, resulting in a design of a loader bucket structure and assembly method. Two key considerations were controlling welding deformation and ensuring the proper dimensions of the mounting holes, ensuring the bucket can be installed and used properly. The key difference between the manual production process and traditional methods is that the three sets of mounting holes are assembled using a sleeve-type construction. A 3mm allowance is added to the lug plates when the holes are cut, and the sleeves are machined to the required dimensions. After the bucket is welded, the three sleeves are welded together, and a simple tooling system is used to ensure the relative dimensions of the three sets of holes. The finished bucket is the same size after welding, eliminating the need for post-welding boring in a machining center. To control welding deformation, manual welding requires a grid-like support frame within the bucket cavity during welding. Anti-deformation braces are also welded to the opposite sides of the three mounting holes. Braces are also welded to the three lug plates before welding to prevent deformation. The support frame and braces are removed after the weld cools. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a schematic diagram of the planar structure of the present invention.

[0036] Figure 2 It is a side view of the present invention. DETAILED DESCRIPTION

[0037] In order to enable those skilled in the art to more clearly understand the objectives, technical solutions and advantages of the present invention, the present invention is further described below with reference to the accompanying drawings and embodiments.

[0038] In the description of the present invention, it should be understood that the orientations or positional relationships indicated by terms such as “upper”, “lower”, “left”, “right”, “inside”, “outside”, “horizontal” and “vertical” are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention, rather than indicating or implying that the device or component referred to must have a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0039] The present invention will be described in detail below with reference to the accompanying drawings: Figure 1 As shown, a loader bucket structure comprises a loader bucket body 1, with a left blade 2 and a right blade 3 welded to both sides of the body, the loader bucket body 1 is concave inward to form a large arc-shaped structure 4 on the back, and a reinforcing bent plate 5 is arranged above and below the arc structure 4, wherein a small bent plate 6 is welded on the left blade 2 and the right blade 3 in front of the upper reinforcing bent plate, an inner reinforcing bent plate 7 is welded below the small bent plate 6, a bottom plate 8 parallel to the ground is welded in front of the lower reinforcing bent plate 7, a main blade 9 is arranged in front of the bottom plate 8, and two upper side ribs 10 arranged in a mirror image are welded to the upper reinforcing bent plate 7, and at least one ear plate assembly 11 and an intermediate plate assembly 12 are arranged between the upper and lower reinforcing bent plates, and a limiting pad 13 is arranged above the ear plate assembly 11.

[0040] There are two ear plate assemblies 11, which are respectively installed on the left and right sides of the middle plate assembly 12 and are separated from the middle plate assembly 12 by a certain distance. Each ear plate assembly 11 is composed of two ear plates 15 with through holes, which are connected by a central sealing plate 16 in the middle. The upper part is fixed on an ear plate reinforcement plate 17, and the lower part is fixed on the inner sealing plate 18. The rear end sealing plates 19 are respectively installed on the left and right sides of the inner sealing plate 18, and a limiting pad 13 is fixed above each ear plate reinforcement plate 17, and a first shaft sleeve 27 is welded in the through hole.

[0041] The intermediate plate assembly 12 is composed of two center plates 20 with through holes 14. The upper part of the center plate 20 is fixed on the center cover plate 21, and the lower part is fixed on the center lower plate 22. A plurality of center ribs 23 are arranged below the center cover plate 21 to increase its strength. A plurality of center outer ribs 24 are arranged on the outer side of the center plate 20, and a second shaft sleeve 28 is welded in the through hole 14.

[0042] The upper rib plate 10 is provided with a lifting hole 25 for facilitating lifting. The upper rib plate 10 is arranged in an "eight" structure.

[0043] Figure 2 As shown, at least one reinforcing plate 26 is welded to the left blade plate 2 and the right blade plate 3 .

[0044] A manual welding method for the loader bucket structure, comprising the following steps:

[0045] 1) Cutting;

[0046] 2) Grinding and deburring;

[0047] 3) Leveling;

[0048] 4) Bending, rounding or metal processing;

[0049] 5) Each component is manually assembled and welded;

[0050] 6) Assembly points;

[0051] 7) Add a grid-mounted support frame to the bucket cavity;

[0052] 8) Add welding strips to the parts prone to deformation;

[0053] 9) Weld the bucket as a whole;

[0054] 10) Cooling;

[0055] 11) Calibration;

[0056] 12) Use simple tooling to assemble three sets of bushings;

[0057] 13) Test the three sets of assembled sleeves;

[0058] 14) Through the core rod, welding is done with simple tooling;

[0059] 15) Detect three sets of hole sizes;

[0060] 16) Grind the entire surface to remove burrs and spatter;

[0061] 17) Overall shot blasting;

[0062] 18) Integral assembly of loader bucket and side teeth;

[0063] 20) Overall paint;

[0064] 21) Storage.

[0065] The specific methods of steps 1-6 are:

[0066] The whole piece of plate is bent by a bending machine, and the bent plate has a rough shape. Then it is further processed by grinding to remove burrs, leveling, bending, rounding, etc., and other small parts are processed as hardware. Small parts are first welded and assembled, such as the left and right blades, as well as the limit pads, ear plates, and center plates. Then the overall structure is roughly connected by spot welding to form a bucket.

[0067] The specific method of steps 7-11 is: a grid-shaped support frame is installed on the inner side of the arc of the general shape after spot welding to prevent deformation, and tie rods are spot welded on the top and bottom. After installation, the entire bucket is welded as a whole, including the limit pad, ear plate, and center plate, and cooled and corrected after welding.

[0068] The specific method of steps 12-21 is: after the installation is completed, install the shaft sleeves in the ear plate and the center plate, first spot-join the shaft sleeves, and then inspect them after spot-joining. Then, insert a core rod into the through holes of the ear plate and the center plate on both sides, wherein the core rod in the center plate is at the top, and the core rods of the ear plates on both sides are at the bottom. After the core rod on the center plate and the core rod between the ear plates on both sides are fixed horizontally through simple tooling, insert the shaft sleeves on the core rods and weld them at the same time. Finally, check whether the size of the hole meets the standard, and finally polish the whole to remove burrs and spatter; shot blast the whole; assemble the loader bucket and side teeth as a whole; paint the whole; and put into storage.

[0069] The traditional process for producing a loader bucket generally involves the following steps: 1. Cutting; 2. Grinding and deburring; 3. Leveling; 3. Bending, rounding, or metalworking; 4. Component assembly and welding; 5. Component welding; 6. Assembly and welding; 7. Assembly welding; 8. Calibration; 9. Metalworking of the three mounting holes and surfaces on a machining center; 10. Overall grinding to remove burrs and spatter; 11. Overall shot blasting; 12. Assembly of the loader bucket and side teeth; 13. Overall painting; 14. Storage. The traditional process involves equipment such as component assembly and welding tools, assembly assembly and welding tools, and an assembly machining center. Welding deformation is guaranteed by the assembly and welding tools, while final dimensions are guaranteed by the machining center.

[0070] The main features of the present invention are two points. One is to control welding deformation; the other is to ensure the size of the mounting holes so that the bucket can be installed and used normally. It is particularly pointed out that the biggest difference between the manual production process and the traditional process is that the three sets of mounting holes in the manual production adopt a sleeve structure. When the ear plates are cut, a 3MM margin is left in the holes. The sleeves are processed to the installation size. After the bucket is welded as a whole, the three sets of sleeves are welded, and simple tooling is used to ensure the relative position and size of the three sets of holes. After welding, the finished bucket size is obtained, and there is no need to go to the machining center for boring after welding. In terms of controlling welding deformation, manual welding has no tooling guarantee, so a grid-mounted support frame needs to be built in the bucket cavity during welding. Anti-deformation pull strips need to be welded on the reverse side of the three sets of mounting holes. Pull strips also need to be welded to the three sets of ear plates to prevent deformation before welding. After welding and cooling, the support frame and pull strips are removed.

[0071] The structure and manual welding method of the present invention are applicable to situations where there are no tooling molds and equipment. They are convenient and quick, and there is no welding deformation and the installation size and position are relatively accurate.

[0072] The present invention has the following characteristics:

[0073] 1. Traditional processes rely on tooling, molds, and equipment to ensure production, while the process of the present invention does not, reducing costs. 2. Traditional processes involve welding the circular plates together before machining three sets of mounting hole dimensions. The process of the present invention utilizes a sleeve-type structure, welding three sets of sleeves after the entire plate is welded, resulting in a finished product. 3. Because traditional processes rely on tooling, molds, and equipment, there's no need to weld mesh supports and tie bars within the bucket cavity. The present invention reduces deformation by adding mesh supports and tie bars.

[0074] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by any technician familiar with this technical field within the technical scope disclosed by the present invention should be covered by the scope of protection of the present invention.

Claims

1. A manual welding method for a loader bucket structure, characterized by: The bucket structure includes a loader bucket body, with a left blade and a right blade respectively welded on both sides of the body, the loader bucket body is concave inward to form a large arc-shaped structure on the back, and a reinforcing bent plate is provided above and below the arc structure, wherein a small bent plate is welded to the left and right blades in front of the upper reinforcing bent plate, an inner reinforcing bent plate is welded below the small bent plate, a bottom plate parallel to the ground is welded in front of the lower reinforcing bent plate, a main blade is arranged in front of the bottom plate, and two upper side ribs arranged in a mirror image are welded to the upper reinforcing bent plate, and at least one ear plate assembly and an intermediate plate assembly are arranged between the upper and lower reinforcing bent plates, and a limiting pad is arranged above the ear plate assembly; the ear plate assembly has a total of two , respectively installed on the left and right sides of the middle plate assembly and separated by a certain distance from the middle plate assembly, each ear plate assembly consists of two ear plates with through holes, connected in the middle by a center sealing plate, fixed on the top to an ear plate reinforcement plate, and fixed on the inner sealing plate at the bottom, and rear end sealing plates are respectively installed on the left and right sides of the inner sealing plate, and a limiting pad is fixed above each ear plate reinforcement plate, and a first shaft sleeve is welded in the through hole; the middle plate assembly consists of two center plates with through holes, the top of the center plate is fixed to the center cover plate, and the bottom is fixed to the center lower plate, and a plurality of center rib plates are arranged under the center cover plate to increase its strength, and a plurality of center outer rib plates are arranged on the outside of the center plate, and a second shaft sleeve is welded in the through hole; The method comprises the following steps: 1) Cutting; 2) Grinding and deburring; 3) Leveling; 4) Bending, rounding or metal processing; 5) Each component is manually assembled and welded; 6) Assembly points; 7) Add a grid-mounted support frame to the bucket cavity; 8) Add welding strips to the parts prone to deformation; 9) Weld the bucket as a whole; 10) Cooling; 11) Calibration; 12) Use simple tooling to assemble three sets of sleeves; 13) Test the three sets of assembled bushings; 14) Through the core rod, welding is done with simple tooling; 15) Detect three sets of hole sizes; 16) Grind the entire surface to remove burrs and spatter; 17) Overall shot blasting; 18) Integral assembly of loader bucket and side teeth; 20) Overall paint; 21) Storage.

2. The manual welding method according to claim 1, characterized in that: The specific methods of steps 1-6 are: The whole piece of plate is bent by a bending machine, and the bent plate has a rough shape. It is then further processed through the method of steps 2-4, and other small parts are processed as hardware. The small parts are first welded and assembled, and then the overall structure is roughly connected by spot welding to form a bucket.

3. The manual welding method according to claim 1, characterized in that: The specific method of steps 7-11 is: a grid-shaped support frame is installed on the inner side of the arc of the general shape after spot welding to prevent deformation, and tie rods are spot welded on the top and bottom. After installation, the entire bucket is welded as a whole, including the limit pad, ear plate, and center plate, and cooled and corrected after welding.

4. The manual welding method according to claim 1, characterized in that: The specific method of steps 12-21 is: after the installation is completed, install the shaft sleeves in the ear plate and the center plate, first spot-join the shaft sleeves, and then inspect them after spot-joining. Then, insert a core rod into the through holes of the ear plate and the center plate on both sides, wherein the core rod in the center plate is at the top, and the core rods of the ear plates on both sides are at the bottom. After the core rod on the center plate and the core rod between the ear plates on both sides are fixed horizontally through simple tooling, insert the shaft sleeves on the core rods and weld them at the same time. Finally, check whether the size of the hole meets the standard, and finally polish the whole to remove burrs and spatter; shot blast the whole; assemble the loader bucket and side teeth as a whole; paint the whole; and put into storage.

5. The manual welding method for a loader bucket structure according to claim 1, characterized in that: The upper rib plate is provided with lifting holes for facilitating lifting, and the upper rib plate is arranged in an eight-shaped structure.

6. The manual welding method for a loader bucket structure according to claim 1, characterized in that: At least one reinforcing plate is welded to the left blade plate and the right blade plate.

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