A machining process for a large reel

Abstract

The application provides a machining process of a large reel device, which comprises the following steps: machining a baffle assembly and a cylinder body respectively, assembling the baffle assembly and the cylinder body by using an open edge clamping sleeve type distance flange, resistance heating tape and an adjustable thrust support rod, simulating and calculating stress and strain values by using three-dimensional analysis software during the assembling, pre-applying force in the opposite direction by using the adjustable thrust support rod before welding operation, monitoring the change of stress in real time during the welding process, adjusting the welding position in time to eliminate the influence of welding thermal stress, and carrying out heating and heat preservation treatment on the welding position after the welding is completed, so that the problem of difficult production and manufacturing of the large reel is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of machining, in particular to a machining process of a large reel device. BACKGROUND

[0002] With the rapid development of modern science and technology, the expansion of industrial production scale and the improvement of automation degree, cranes are applied more and more widely in modern production process. In the hoisting machinery, the reel is an important load-bearing component of the crane, which controls the winding and unwinding of the steel wire rope through the action of the power system to realize the lifting or lowering function when the crane hoists heavy objects. It bears the lifting load of the crane, so its safety and reliability directly affect the lifting, amplitude, traction and other working characteristics of the crane. At present, the domestic crane reel is mostly made of cast steel cylinder butt welding and steel plate roll welding. The cast steel cylinder butt welding is suitable for processing small reels, and the steel plate roll welding is suitable for processing large reels. Large reels are applied to cargo cranes in ports or large ships, and the diameter of the reel can reach more than one meter, and the diameter of the reel baffle can reach more than two meters. Such a reel can only be processed by welding.

[0003] A reel welding method is disclosed in a patent document with the application date of September 6, 2017, the application number of 201710795910.7, and the application publication number of CN 107598447A. The method includes providing a cylinder shell and two spoke assemblies; assembling and positioning the two spoke assemblies at both ends of the cylinder shell; fixing and connecting the middle parts of the two spoke assemblies with a positioning rod, which is located inside the cylinder shell; positioning between the spoke assembly and the cylinder shell with a positioning plate; welding the spoke assemblies at both ends of the cylinder shell with the cylinder shell respectively to obtain a reel. This scheme can prevent the welding deformation and welding cold cracks of the reel to a certain extent when processing a specific reel.

[0004] The two spoke assemblies of this scheme are welded inside the cylinder shell, and the structure is not a conventional structure and is relatively simple, which is suitable for light load and medium size occasions. However, for larger size occasions, such as baffle diameter reaching more than two meters and needing to bear heavy load, this welding method is not suitable. SUMMARY

[0005] To solve the problems in the prior art, the present application provides a machining process for a large reel device. The baffle assembly and the cylinder are machined separately by using a suitable process, and then the baffle assembly and the cylinder are assembled together to solve the problem of difficult production and manufacturing of large reels.

[0006] To achieve the above-mentioned purpose, the technical scheme of the present application is as follows: a machining process for a large reel device, comprising the following steps:

[0007] a. Cylinder manufacturing, after the plate is cut, it is flattened, rolled, welded, inspected, annealed or vibrated to eliminate welding stress, machined to the right position, and re-inspected.

[0008] b. First and second baffle assembly manufacturing, after the plate is cut, it is flattened, partially rolled, structural assembly, welded, inspected, annealed or vibrated to eliminate welding stress, machined to the right position, owner weld and auxiliary weld, re-inspected.

[0009] c. Provide open edge sleeve type distance flange, resistance heating tape, adjustable thrust support rod and other tooling fixtures.

[0010] d. Install the open edge sleeve type distance flange on the outer circle of the cylinder, adjust the position of the open edge sleeve type distance flange according to the distance between the first and second baffle assemblies on both sides of the cylinder, lock it in place, and recheck the distance between the two open edge sleeve type distance flanges.

[0011] e. Lay the resistance heating tape at the outer circumference of the first and second baffle assemblies and the cylinder mating parts and heat it, then sleeve the first and second baffle assemblies onto the cylinder, so that the inner side of the first and second baffle assemblies tightly abuts the side of the open edge sleeve type distance flange, and the auxiliary weld is electrically welded and fixed.

[0012] f. Install more than three adjustable thrust support rods between the first and second baffle assemblies, simulate and calculate the stress and strain values through three-dimensional analysis software, and pre-apply the simulated calculation force in the opposite direction through the adjustable thrust support rods before welding operation; remove the open edge sleeve type distance flange; lay the resistance heating tape at the main weld and heat it, remove the resistance heating tape after reaching the set temperature, start welding, and monitor the stress changes in real time during welding, and adjust the welding position in time to eliminate the influence of welding thermal stress until the welding is completed.

[0013] g. Lay the resistance heating tape on the welded part and heat it, keep it warm for 8-10 hours, remove the resistance heating tape, and cool it to room temperature.

[0014] The above process first processes the cylinder, the first baffle assembly and the second baffle assembly according to the requirements, which can minimize the accumulation of errors.

[0015] Use the open edge sleeve type distance flange, loosen the bolts on the open edge sleeve type distance flange, which can move axially on the cylinder; tighten the bolts to lock them as the axial positioning reference of the baffle assembly, and the baffle assembly tightly abuts the open edge sleeve type distance flange to meet the design requirements of the baffle spacing. This positioning method is simple to operate and has high positioning accuracy.

[0016] The first baffle assembly and the second baffle assembly are heated by using resistance heating tape, and are installed by using a heat fitting process. After installation, the first baffle assembly and the second baffle assembly are cooled to form an interference fit and tightly wrap the cylinder.

[0017] The adjustable thrust support rod can easily adjust the distance between the first baffle assembly and the second baffle assembly.

[0018] The welded part is heated and kept warm by step g, which is equivalent to tempering treatment of the welded part, eliminating residual stress, stabilizing the size, and improving the toughness of the material.

[0019] Further, the adjustable thrust support rod is a double-end screw rod with a force sensor, and the two ends are provided with threads in opposite directions.

[0020] Through the rotation of the screw rod, the nut can be adjusted to move outward or inward, generating a force to outwardly support or inwardly collect the baffle. The force value is displayed by the force sensor, and the pre-tightening force of the nut is adjusted according to the actual needs to be consistent with the simulated calculation stress.

[0021] Further, in step f, a three-dimensional model is established by using three-dimensional analysis software. According to the welding form and welding size at the welding position, the number of layers of the weld, the welding time, the process of welding heat release, and the deformation influence of internal stress on the model size are simulated and calculated.

[0022] The above process is a preventive production measure, which has obvious effect on the stability of the size after welding.

[0023] Further, in step e, the outer circumferential part of the first baffle assembly and the second baffle assembly and the cylinder fitting part is heated to 120-150℃ by using resistance heating tape. Heating to this temperature range can increase the diameter of the hole of the first baffle assembly and the second baffle assembly, and can easily assemble the cylinder.

[0024] Further, in step f, the main weld is heated to 120-180℃ by using resistance heating tape. Heating to this temperature range can reduce 90% of the welding heat deformation.

[0025] Further, in step g, the welded part is heated to 180℃ by using resistance heating tape, and is kept warm for 8-10 hours. Heating to this temperature can more completely eliminate residual stress and stabilize the size. BRIEF DESCRIPTION OF DRAWINGS

[0026] Fig. 1 It is a schematic view of the open edge sleeve type fixed distance flange installed on the cylinder;

[0027] Fig. 2 It is a schematic view of the first baffle assembly and the second baffle assembly installed on the cylinder;

[0028] Fig. 3 This is the left view of the roll. Detailed Implementation

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

[0030] like Figs. 1-3 As shown, the assembly and welding process of a large drum device includes the following steps:

[0031] a. Manufacturing of cylinder 1: After the plate material is cut, it is leveled, rolled into shape, welded at the welding bevel, welded, inspected, annealed or vibrated to eliminate welding stress, machined to the required position, and inspected again.

[0032] b. Fabrication of the first baffle assembly 2 and the second baffle assembly 3: After the plate material is cut, welding bevels are opened, leveling is performed, partial rolling is carried out, structural components are assembled, welded, inspected, annealed or vibrated to eliminate welding stress, machined to the required position, main welds and auxiliary welds are machined, and inspected again.

[0033] c. Provide tooling and fixtures such as open-edge compression fitting fixed-distance flange 4, resistance heating tape, and adjustable thrust support rod 5.

[0034] d. For example Fig. 1 As shown, the open-side ferrule-type spacer flange 4 is installed on the outer circle of the cylinder 1. The position of the open-side ferrule-type spacer flange 4 is adjusted according to the distance between the first baffle assembly 2 and the second baffle assembly 3 on both sides of the cylinder 1. After it is in place, it is locked, and the distance between the two open-side ferrule-type spacer flanges 4 is checked again. Using the open-side ferrule-type spacer flange 4, after the bolts on the open-side ferrule-type spacer flange 4 are loosened, it can move axially on the cylinder 1. After the bolts are tightened and locked, it serves as the axial positioning reference for the first baffle assembly 2 and the second baffle assembly 3. The first baffle assembly 2 and the second baffle assembly 3 are close to the open-side ferrule-type spacer flange 4, which meets the design requirements for the distance between the first baffle assembly 2 and the second baffle assembly 3. This positioning method is simple to operate and has high positioning accuracy.

[0035] e. Lay the resistance heating tape on the outer circumference of the part where the first baffle assembly 2 and the second baffle assembly 3 meet the cylinder 1 and heat it. After reaching the set temperature, put the first baffle assembly 2 and the second baffle assembly 3 onto the cylinder 1, so that the inner side of the first baffle assembly 2 and the second baffle assembly 3 are tightly attached to the side of the open-side compression fitting spacer flange 4 and the auxiliary weld seam is fixed by electric welding.

[0036] f. Install three or more adjustable thrust struts 5 between the first baffle assembly 2 and the second baffle assembly 3. Using 3D analysis software, establish a 3D model. Based on the welding method and welding size, subdivide the number of weld layers and welding time at the welding position. Simulate and calculate the process of welding heat release and the influence of internal stress on the deformation of the model size. Simulate and calculate stress and strain values. Before welding, apply the simulated opposite force through the adjustable thrust struts 5. Monitor stress changes in real time during welding and adjust the welding position as needed to eliminate the influence of welding thermal stress.

[0037] The adjustable thrust support rod 5 is a double-ended screw with a force sensor. The threads at both ends are in opposite directions. By rotating the screw, the adjustable nut can move outward or inward, generating a force that pushes the first baffle assembly 2 outward or retracts the second baffle assembly 3. The force sensor displays the force value, and the preload of the nut can be adjusted according to actual needs to make it consistent with the simulated stress obtained from the three-dimensional analysis.

[0038] Remove the open-end clamp-type spacer flange 4; lay the resistance heating tape on the main weld seam and heat it to 120-180℃. After reaching the set temperature, remove the resistance heating tape and start welding. Continue welding until the welding is completed.

[0039] g. Lay the resistance heating tape on the welded area and heat it to 180°C. Keep it warm for 8-10 hours, then remove the resistance heating tape and let it cool to room temperature.

[0040] This processing technology involves first machining the cylinder 1, the first baffle assembly 2, and the second baffle assembly 3 separately, and then assembling the cylinder 1, the first baffle assembly 2, and the second baffle assembly 3 together. During assembly, tooling fixtures such as the open-edge clamping flange 4, resistance heating tape, and adjustable thrust support rod 5 are used. Stress and strain values ​​are simulated and calculated in advance, which can minimize the impact of stress generated during welding on the drum, prevent drum deformation, and solve the problem of difficult production and manufacturing of large drums.

Claims

1. An assembly and welding process for a large reel, characterized in that, It comprises the following steps: a. Cylinder manufacturing, after the plate is cut, it is flattened, formed, welded, inspected, annealed or vibrated to eliminate welding stress, machined to the right position, and re-inspected; b. First and second baffle assembly manufacturing, after the plate is cut, it is flattened, partially formed, structural assembly, welded, inspected, annealed or vibrated to eliminate welding stress, machined to the right position, main weld and auxiliary weld, and re-inspected; c. Open edge sleeve type distance flange, resistance heating tape, adjustable thrust support rod tool clamp are provided; d. The open edge sleeve type distance flange is installed on the outer circle of the cylinder, the position of the open edge sleeve type distance flange is adjusted according to the distance between the first and second baffle assemblies on both sides of the cylinder, locked after being in place, and the distance between the two open edge sleeve type distance flanges is rechecked; e. The resistance heating tape is laid on the outer circumference of the cylinder at the position where the first and second baffle assemblies and the cylinder cooperate and heated, after reaching the set temperature, the first and second baffle assemblies are sleeved on the cylinder, and the inner side of the first and second baffle assemblies is tightly attached to the side of the open edge sleeve type distance flange, and the auxiliary weld is electrically welded and fixed; f. More than three adjustable thrust support rods are installed between the first and second baffle assemblies, the stress and strain values are simulated and calculated through three-dimensional analysis software, and the opposite direction force is pre-applied through the adjustable thrust support rod before welding operation; The open edge sleeve type distance flange is removed, the resistance heating tape is laid on the main weld and heated, the resistance heating tape is removed after reaching the set temperature, and welding is started, the stress change is monitored in real time during welding, and the welding position is adjusted in time to eliminate the influence of welding thermal stress until welding is completed; g. The resistance heating tape is laid on the welded part and heated, and the temperature is kept for 8-10 hours, the resistance heating tape is removed, and the temperature is lowered to normal temperature.

2. An assembly and welding process for a large drum as claimed in claim 1, wherein: The adjustable thrust support rod is a double-head screw rod with a force sensor, and the threads at both ends are opposite in rotation direction.

3. A process for assembling and welding a large drum as claimed in claim 1, wherein: In step f, a three-dimensional model is established through three-dimensional analysis software, the welding position is subdivided according to the welding form and size, the number of weld layers and welding time are subdivided, and the process of welding heat release and the influence of internal stress on model size are simulated and calculated.

4. The process of assembling and welding a large drum as claimed in claim 1, wherein: In step e, the outer circumference of the cylinder at the position where the first and second baffle assemblies cooperate is heated to 120-150℃ by the resistance heating tape.

5. The process of assembling and welding a large drum as claimed in claim 1, wherein: In step f, the main weld is heated to 120-180℃ by the resistance heating tape.

6. An assembly and welding process for a large drum as defined in claim 1, wherein: In step g, the welded part is heated to 180℃ by the resistance heating tape.

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