Manufacturing method of replaceable middle groove side wall

Abstract

The present application relates to the technical field of middle trough, and discloses a replaceable middle trough trough help manufacturing method, which comprises the following steps: S1, cleaning the easy-wearing parts of the inner recess of the middle trough trough help; S2, replacing the easy-wearing parts of the inner recess of the middle trough trough help with 10-15mm-thick inner recess profiling structure wear-resistant plates; S3, the wear-resistant plates are of different thicknesses according to the well conditions, so that the wear-resistant plates are convenient for quick replacement and maintenance in the later period, and the trough help body is protected from wearing; S4, the wear-resistant plates are connected and fixed to the trough help body by using a plunger medicine core wear-resistant welding wire fusion welding mode; and S5, the wear-resistant plates are made of 5-10mm low-alloy steel materials as base materials, and the base material surfaces are prepared with 5-10mm wear-resistant layers by using a wear-resistant alloy powder surfacing method. The present application can make the trough help body be recycled, save resources, and make the wear-resistant maintenance in the later period be convenient and fast, and solve the problems of excessive heat input deformation of the groove size filling and surfacing.

Description

Technical Field

[0001] This invention relates to the field of center channel technology, and more particularly to a method for manufacturing an interchangeable center channel sidewall. Background Technology

[0002] Currently, the central trough of a scraper conveyor is mainly used in underground scraper conveyors and transfer conveyors in coal mines. The central trough is the body of the scraper conveyor, composed of a central plate and sidewalls. The upper trough transports coal, while the lower trough provides the return path for the scraper chain. It serves as the running track for the scraper chain, the running track for the coal mining machine, and the running channel for the coal load. During underground use, the central trough experiences severe wear due to factors such as scrapers, coal chunks, and gangue, sometimes even leading to complete wear and tear. The sidewalls of the central trough are conventionally cast, which, on the one hand, requires the entire sidewall to be scrapped due to severe wear, wasting steel resources and increasing the cost of new parts; on the other hand, uneven wear on the sidewalls results in uneven repair thickness, increasing the difficulty of subsequent maintenance and making it difficult to guarantee the quality and dimensional requirements of the repaired sidewalls. Summary of the Invention

[0003] To address the challenges of post-repair maintenance and the difficulty in ensuring the quality and dimensional requirements of the inner cavity of the channel wall after repair, this invention provides a method for manufacturing an interchangeable central channel wall.

[0004] This invention is achieved using the following technical solution: a method for manufacturing an adjustable central groove sidewall, comprising the following steps:

[0005] S1. Clean the easily worn parts of the inner groove of the middle groove;

[0006] S2. Replace the easily worn parts of the inner groove sidewall with a 10~15mm thick inner groove contour structure wear-resistant plate;

[0007] S3. The wear-resistant plate can be selected with different thicknesses according to the well conditions, which facilitates quick replacement and maintenance in the later stage and protects the trench side body from wear.

[0008] S4. The wear-resistant plate and the groove body are connected and fixed by plunger-cored wear-resistant welding wire fusion welding;

[0009] S5. The wear-resistant plate uses 5-10mm low alloy steel as the base material, and the surface of the base material is prepared with a 5-10mm wear-resistant layer by means of wear-resistant alloy powder overlay welding.

[0010] As a further improvement to the above solution, the plunger fixing is specifically as follows:

[0011] (1) Use low melting point brazing filler metal for fastening. First, braze the plunger to fix it on the groove body, and then pass the conformal wear-resistant plate through the positioning plunger.

[0012] (2) The plunger height is 1~3mm lower than the wear-resistant plate thickness, and it is brazed and fixed by filling with a flux with good self-lubricating properties.

[0013] As a further improvement to the above scheme, the composition of the wear-resistant alloy powder is: Cr: 25%~40%, Ni: 1%~5%, C: 3%~6%, Si: 1%~5%, Mn: 1%~8%, V: 1~8%, Mo: 1~5%, W: 0.5~3.5%. The Ni, Cr and Mo can improve the toughness, hardenability and corrosion resistance of the material, the Mn and Si can strengthen the iron matrix, and the Cr can ensure the hardenability and corrosion resistance of the channel steel.

[0014] As a further improvement to the above solution, before using the wear-resistant plate, a protective coating is applied to the surface of the wear-resistant plate to prevent decarburization and oxidation of the surface of the wear-resistant plate due to excessively high temperature during heat treatment.

[0015] As a further improvement to the above solution, the central groove is repaired and remanufactured using plasma cladding technology, which can further improve the wear resistance of the cladding layer of the central groove.

[0016] As a further improvement to the above scheme, the surface of the cladding layer of the groove side is analyzed by X-ray diffraction. It can be seen that the phases in the cladding layer are mainly composed of γ-(Fe,Ni), (Cr,Fe)7(C,B)3, and γ-Fe phases. Moreover, the carbide phase in the structure increases the microhardness of the cladding layer to a certain extent and improves the wear resistance of the middle groove.

[0017] As a further improvement to the above solution, the wear-resistant plate has a hardness of 450HB, and the convex and concave heads between the central grooves are integrally processed after welding. The convex head is improved from a flat surface to a spherical shape. When the central groove bends, the rotation center and positioning accuracy remain unchanged, which can reduce power consumption, reduce wear at the end of the central groove, and accurately control the bending of the central groove.

[0018] As a further improvement to the above solution, the welding of the central groove involves only two straight weld seams, and the welding is performed using a KUKA KR16 welding robot.

[0019] As a further improvement to the above solution, the welding is performed using wear-resistant welding wire, which includes alloying elements such as chromium, molybdenum alloy, manganese, silicon, and nickel.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0021] This invention allows the groove body to be reused, saving resources. It also makes subsequent maintenance easier and faster due to wear resistance, and solves problems such as excessive heat input and deformation during groove filling and welding. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the central groove of the present invention. Detailed Implementation

[0023] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0024] Please combine Figure 1 The method for manufacturing the interchangeable middle channel sidewalls in this embodiment includes the following steps:

[0025] S1. Clean the easily worn parts of the inner groove of the middle groove;

[0026] S2. Replace the easily worn parts of the inner groove sidewall with a 10~15mm thick inner groove contour structure wear-resistant plate;

[0027] S3. The wear-resistant plate can be selected with different thicknesses according to the well conditions, which facilitates quick replacement and maintenance in the later stage and protects the trench side body from wear.

[0028] S4. The wear-resistant plate and the groove body are connected and fixed by plunger-cored wear-resistant welding wire fusion welding;

[0029] S5. The wear-resistant plate uses 5-10mm low alloy steel as the base material, and the surface of the base material is prepared with a 5-10mm wear-resistant layer by means of wear-resistant alloy powder overlay welding.

[0030] The plunger fixing is specifically as follows:

[0031] (1) Use low melting point brazing filler metal for fastening. First, braze the plunger to fix it on the groove body, and then pass the conformal wear-resistant plate through the positioning plunger.

[0032] (2) The plunger height is 1~3mm lower than the wear-resistant plate thickness, and it is brazed and fixed by filling with a flux with good self-lubricating properties.

[0033] The plunger fixation has the following characteristics:

[0034] (1) The plunger is fixed on the groove body, which can form a tight connection between the wear-resistant plate and the groove body, increasing the stability and wear resistance of the wear-resistant plate, extending its service life. After the plunger is fixed, the position of the wear-resistant plate is fixed and there will be no displacement or loosening, which can maintain the normal operation of the equipment and improve work efficiency.

[0035] (2) Plunger fixing can reduce wear and damage to the wear plate, reduce the frequency of replacement and maintenance, and thus reduce maintenance costs.

[0036] (3) Plunger fixing can prevent the wear-resistant plate from falling off or loosening, thus avoiding potential safety hazards that may cause personal injury or equipment failure.

[0037] Therefore, plunger fixing can not only improve the stability and durability of the equipment, but also reduce maintenance costs and improve work efficiency and safety.

[0038] The wear-resistant alloy powder has the following composition: Cr: 25%~40%, Ni: 1%~5%, C: 3%~6%, Si: 1%~5%, Mn: 1%~8%, V: 1~8%, Mo: 1~5%, W: 0.5~3.5%. Ni, Cr and Mo can improve the toughness, hardenability and corrosion resistance of the material, Mn and Si can strengthen the iron matrix, and Cr can ensure the hardenability and corrosion resistance of the channel steel.

[0039] Before use, the wear-resistant plate is coated with a protective coating to prevent decarburization and oxidation of the wear-resistant plate surface due to excessively high temperature during heat treatment.

[0040] The central groove is repaired and remanufactured using plasma cladding technology, which can further improve the wear resistance of the cladding layer in the central groove.

[0041] X-ray diffraction analysis of the cladding layer surface revealed that the cladding layer is mainly composed of γ-(Fe,Ni), (Cr,Fe)7(C,B)3, and γ-Fe phases. Furthermore, the carbide phases in the microstructure increase the microhardness of the cladding layer to a certain extent, thereby improving the wear resistance of the central groove.

[0042] The wear-resistant plate has a hardness of 450HB. The convex and concave heads between the central grooves are integrally processed after welding. The convex head is improved from a flat surface to a spherical shape. When the central groove bends, the rotation center and positioning accuracy remain unchanged, which can reduce power consumption, reduce wear at the end of the central groove, and accurately control the bending of the central groove.

[0043] The welding of the central groove consists of only two straight weld seams, and the welding is performed using a KUKA KR16 welding robot.

[0044] The KUKA KR16 welding robot is highly automated and can complete complex welding tasks, improving production efficiency and quality stability. The robot welding also has high precision, accurately controlling the welding position, speed and force to ensure the quality and consistency of the weld.

[0045] Robotic welding is fast, enabling it to complete welding tasks quickly and improve production efficiency. Robotic welding also has good repeatability, ensuring consistent welding quality and reducing the impact of human factors on welding quality.

[0046] Robotic welding can reduce the risks of manual welding and improve the safety of the working environment. The KUKA KR16 welding robot has high flexibility and can adapt to welding workpieces of different shapes and sizes, providing customized welding solutions.

[0047] Therefore, using the KUKA KR16 welding robot for welding the middle tank has advantages such as high automation, high precision, fast welding speed, good repeatability, personnel safety, and high flexibility, which can improve production efficiency and welding quality.

[0048] The welding is performed using wear-resistant welding wire, which includes alloying elements such as chromium, molybdenum alloy, manganese, silicon, and nickel.

[0049] Wear-resistant welding wire has the following characteristics:

[0050] (1) The alloying elements in wear-resistant welding wire can provide excellent wear resistance, making the welded part have high wear resistance and resist wear and friction;

[0051] (2). The alloying elements in wear-resistant welding wire can improve the hardness of the welded part, giving it higher compressive strength and wear resistance, and enabling it to maintain stability under high load and harsh working conditions;

[0052] (3) The alloying elements in wear-resistant welding wire can provide good corrosion resistance, enabling the welded part to resist the erosion of corrosive media such as acids, alkalis and salts, and extend its service life;

[0053] (4) Wear-resistant welding wire has a high melting point and thermal stability, and can maintain stable welding performance in high-temperature environments, and is not easily melted or deformed;

[0054] Therefore, welding with wear-resistant welding wire not only has good welding performance, but also can form a good bond with other metal materials, resulting in a strong and reliable welded joint. Thus, welding with wear-resistant welding wire has the advantages of strong wear resistance, high hardness, good corrosion resistance, good thermal stability, and ease of welding.

[0055] This invention allows the groove body to be reused, saving resources. It also makes subsequent maintenance easier and faster due to wear resistance, and solves problems such as excessive heat input and deformation during groove filling and welding.

[0056] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A method for manufacturing an interchangeable central groove sidewall, characterized in that, Includes the following steps: S1. Clean the easily worn parts of the inner groove of the middle groove; S2. Replace the easily worn parts of the inner groove of the central groove with a 10-15mm thick inner groove conforming structure wear-resistant plate; S3. The wear-resistant plate is selected with different thicknesses according to the well conditions, which facilitates quick replacement and maintenance in the later stage and protects the trench side from wear. S4. The wear-resistant plate and the groove body are connected and fixed by plunger-cored wear-resistant welding wire fusion welding; S5. The wear-resistant plate uses 5-10mm low alloy steel as the base material, and the surface of the base material is prepared with a 5-10mm wear-resistant layer by means of wear-resistant alloy powder overlay welding. The plunger fixing is specifically as follows: (1) Use low melting point brazing filler metal for fastening. First, braze the plunger to fix it on the groove body, and then pass the conformal wear-resistant plate through the positioning plunger. (2) The plunger height is 1-3 mm lower than the wear-resistant plate thickness, and it is fixed by brazing with a flux that has good self-lubricating properties; The wear-resistant alloy powder has the following composition: Cr: 25%–40%, Ni: 1%–5%, C: 3%–6%, Si: 1%–5%, Mn: 1%–8%, V: 1–8%, Mo: 1–5%, W: 0.5–3.5%. Ni, Cr, and Mo can improve the toughness, hardenability, and corrosion resistance of the material. Mn and Si can strengthen the iron matrix. Cr can ensure the hardenability and corrosion resistance of the channel steel.

2. The method for manufacturing the interchangeable central groove sidewall as described in claim 1, characterized in that, Before use, the wear-resistant plate is coated with a protective coating to prevent decarburization and oxidation of the wear-resistant plate surface due to excessively high temperature during heat treatment.

3. The method for manufacturing the interchangeable central groove sidewall as described in claim 1, characterized in that, The central groove is repaired and remanufactured using plasma cladding technology, which can further improve the wear resistance of the cladding layer in the central groove.

4. The method for manufacturing the interchangeable central groove sidewall as described in claim 1, characterized in that, The wear-resistant plate has a hardness of 450HB. The convex and concave heads between the central grooves are integrally processed after welding. The convex head is improved from a flat surface to a spherical shape. When the central groove bends, the rotation center and positioning accuracy remain unchanged, which can reduce power consumption, reduce wear at the end of the central groove, and accurately control the bending of the central groove.

5. The method for manufacturing the interchangeable central groove sidewall as described in claim 1, characterized in that, The welding of the central groove consists of only two straight weld seams, and the welding is performed using a welding robot.

6. The method for manufacturing the interchangeable central groove sidewall as described in claim 5, characterized in that, The welding process uses wear-resistant welding wire.

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