A welding tool for a boiler header

Abstract

The application discloses a welding tool for a boiler header, which comprises a first lifting cylinder, a second lifting cylinder and a base mechanism, the bottom of the second lifting cylinder is arranged on the upper end of the base mechanism, the upper end of the second lifting cylinder is connected with a fixing mechanism, the bottom of the first lifting cylinder is arranged on the upper end of the fixing mechanism, the upper end of the first lifting cylinder is connected with a positioning mechanism, the middle part of the upper surface of the base mechanism is provided with a supporting mechanism, the positioning mechanism is provided with a laser emitter, the end surface of the base mechanism is fixedly connected with a control mechanism, and the control mechanism is connected with the laser emitter, the first lifting cylinder, the second lifting cylinder and the fixing mechanism. The tool can realize the fixed clamping of the boiler header and the alignment of the pipeline.

Description

Technical Field

[0001] This invention belongs to the field of boiler header welding technology, and relates to a welding fixture for boiler headers. Background Technology

[0002] Boiler headers, also called manifolds, are composed of water-cooled walls, economizers, and superheaters. These include water-cooled wall headers, economizer headers, and superheater headers. The specific function of boiler headers is to collect or distribute steam and water working fluids, reducing the number of connecting pipes for fluid transport and the number of openings in the boiler drum. This improves the safety of boiler drum operation. Furthermore, lower water-cooled wall headers are located on both sides of the furnace near the grate to prevent coking on the grate sides. Existing boiler headers connect to many heating surface pipes, which are generally made of seamless steel pipes with welded flat end caps or caps at both ends. These pipes are then fixed to the boiler headers by welding, thus requiring the use of welding fixtures in this process.

[0003] Most existing welding fixtures for boiler headers involve fixing and clamping the boiler header, and then having the user align the pipes. In actual operation, adjustments and alignment need to be made based on the user's experience, making the operation difficult and the processing accuracy hard to guarantee, thus limiting their practicality. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a welding fixture for boiler headers, which can achieve the fixed clamping of boiler headers and the alignment of pipes.

[0005] To achieve the above objectives, the present invention discloses a welding fixture for a boiler header, comprising a first lifting cylinder, a second lifting cylinder, and a base mechanism. The bottom of the second lifting cylinder is disposed at the upper end of the base mechanism, and a fixing mechanism is connected to the upper end of the second lifting cylinder. The bottom of the first lifting cylinder is disposed at the upper end of the fixing mechanism, and a positioning mechanism is connected to the upper end of the first lifting cylinder. A support mechanism is disposed in the middle of the upper surface of the base mechanism, and a laser emitter is disposed on the positioning mechanism. A control mechanism is fixedly connected to the end face of the base mechanism, and the control mechanism is connected to the laser emitter, the first lifting cylinder, the second lifting cylinder, and the fixing mechanism.

[0006] The positioning mechanism includes an upper support plate, which is connected to the upper end of the first lifting cylinder. The upper surface of the upper support plate has several mounting holes, and the bottom surface of the upper support plate has several sliding grooves. The emitting end of the laser emitter is inserted into the mounting holes, and the laser emitted by the laser emitter can pass through the mounting holes. The upper end of the clamping block is provided with a slider, which is located in the sliding groove. Two clamping blocks form a pair, and the fixing bolt passes through the clamping block and the slider and contacts the inner wall of the sliding groove.

[0007] The fixing mechanism includes a support platform, a first lifting cylinder is mounted on the support platform, the upper end of a second lifting cylinder is fixed to the bottom of the support platform, a plurality of second linear motors are slidably mounted on the upper surface of the support platform, a second moving plate is fixedly mounted on the upper end of the second linear motors, a plurality of first linear motors are slidably mounted on the upper surface of the second moving plate, a first moving plate is fixedly mounted on the upper end of the first linear motors, a clamping component is mounted on the first moving plate, and a control mechanism is connected to the first linear motors and the second linear motors.

[0008] The clamping component includes a first upright plate, which is disposed on one side of the upper surface of the first movable plate. A second upright plate is fixedly disposed on the other side of the upper surface of the first movable plate. A first telescopic rod is disposed on the side of the first upright plate. A first clamp is fixedly connected to the end of the first telescopic rod away from the first upright plate. A motor housing is fixedly disposed on the side of the second upright plate. A servo motor is fixedly disposed inside the motor housing. The output end of the servo motor passes through the motor housing and through the second upright plate, and is fixedly disposed on the second clamp. The control mechanism is connected to the servo motor and the first telescopic rod.

[0009] The base mechanism includes a lower support plate, and anti-slip pads are fixedly installed at the four corners of the bottom surface of the lower support plate. The second lifting cylinder and the support mechanism are fixed to the lower support plate.

[0010] The support mechanism includes two counterweight boxes, each with a damping shaft rotatably mounted on its upper end. A second telescopic rod is mounted at the middle position of the damping shaft, and a support block is connected to the upper end of the second telescopic rod. The support block has a slot, and one end of the support plate is engaged in the slot on one counterweight box, while the other end of the support plate is engaged in the slot on the other counterweight box.

[0011] The control mechanism includes a connecting plate, one end of which is fixed to the end face of the lower support plate, and the other end of which is connected to the lower end of the third telescopic rod. A control box is fixedly connected to the upper end of the third telescopic rod.

[0012] The front of the control box is equipped with an LCD screen and several control buttons, which are connected to the control box.

[0013] The present invention has the following beneficial effects:

[0014] In specific operation, the welding fixture for boiler headers described in this invention clamps the pipes to be welded through the clamping blocks in the positioning mechanism and positions them through a laser emitter. During welding, the position of the fixing mechanism is adjusted by the control mechanism to align the welding position of the boiler header, reducing the processing difficulty for users during welding operations, improving the overall work efficiency and docking accuracy of welding work, expanding the application range of the device, and enhancing the overall practicality of the device. Attached Figure Description

[0015] Figure 1 This is a front view schematic diagram of the present invention;

[0016] Figure 2 This is a schematic diagram of the front section of the present invention;

[0017] Figure 3 This is a frontal axonometric schematic diagram of the support mechanism in this invention;

[0018] Figure 4 This is a rear-view isometric schematic diagram of the support mechanism in this invention;

[0019] Figure 5 This is an isometric view of the clamping block in this invention;

[0020] Figure 6 This is an isometric schematic diagram of the upper bearing plate in this invention;

[0021] Figure 7 This is an isometric schematic diagram of the support block in this invention.

[0022] Among them, 1 is the positioning mechanism, 2 is the first lifting cylinder, 3 is the fixing mechanism, 4 is the second lifting cylinder, 5 is the base mechanism, 6 is the support mechanism, 7 is the control mechanism, 101 is the laser emitter, 102 is the slide groove, 103 is the mounting hole, 104 is the upper support plate, 105 is the fixing bolt, 106 is the clamping block, 107 is the slider, 301 is the first fixing knob, 302 is the first upright plate, 303 is the first telescopic rod, 304 is the first clamping component, 305 is the second clamping component, 306 is the second fixing knob, 307 is the second upright plate, 308 is the data transceiver, 309 is the motor box, 31 is the... 0 is a servo motor, 311 is the first moving plate, 312 is the first linear motor, 313 is the second moving plate, 314 is the second linear motor, 315 is the support platform, 501 is the anti-slip pad, 502 is the insertion hole, 503 is the lower support plate, 601 is the take-out slot, 602 is the second telescopic rod, 603 is the damping shaft, 604 is the placement slot, 605 is the support block, 606 is the support plate, 607 is the counterweight box, 608 is the handle, 609 is the insertion post, 610 is the slot, 701 is the control box, 702 is the LCD screen, 703 is the control button, 704 is the third telescopic rod, and 705 is the connecting plate. Detailed Implementation

[0023] To enable those skilled in the art to better understand the present invention, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, not all embodiments, and are not intended to limit the scope of the present invention. Furthermore, in the following description, descriptions of well-known structures and technologies are omitted to avoid unnecessary confusion regarding the concepts disclosed in the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort should fall within the scope of protection of the present invention.

[0024] The accompanying drawings show structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not drawn to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0025] refer to Figure 1 The welding fixture for boiler headers described in this invention includes a base mechanism 5. A second lifting cylinder 4 is fixedly installed at each of the four corners of the upper end of the base mechanism 5. A fixing mechanism 3 is fixedly connected to the upper end of the second lifting cylinder 4, which facilitates the user to adjust the overall position of the fixing mechanism 3. A first lifting cylinder 2 is fixedly installed at each of the four corners of the upper end of the fixing mechanism 3.

[0026] The upper ends of the four first lifting cylinders 2 are fixedly connected to positioning mechanisms 1, which facilitates the user to adjust the overall position of the positioning mechanisms 1. Two support mechanisms 6 are provided in the middle of the upper surface of the base mechanism 5, which helps to provide necessary support for the use of the device and improve the overall safety of the device. A control mechanism 7 is fixedly connected to the end face of the base mechanism 5, which facilitates the user to directly control the overall working status of the device. The control mechanism 7 is connected to the laser emitter 101, the first lifting cylinders 2, the second lifting cylinders 4 and the fixing mechanism 3.

[0027] refer to Figure 2 , Figure 5 and Figure 6The positioning mechanism 1 includes an upper support plate 104. The upper surface of the upper support plate 104 is provided with a plurality of mounting holes 103 at equal intervals, and the bottom surface of the upper support plate 104 is provided with a plurality of sliding grooves 102 at equal intervals. The emitting end of the laser emitter 101 is inserted into the mounting hole 103, and the laser emitted by the laser emitter 101 can pass through the mounting hole 103. The upper end of the clamping block 106 is provided with a slider 107, which is located in the sliding groove 102. Two clamping blocks 106 form a pair for clamping a pipe. The fixing bolt 105 passes through the clamping block 106 and the slider 107 and contacts the inner wall of the sliding groove 102 to fix the clamping block 106 and the slider 107, thereby achieving the clamping and fixing of the pipe.

[0028] The fixing mechanism 3 includes a support platform 315. A plurality of second linear motors 314 are slidably mounted on the upper surface of the support platform 315. A second movable plate 313 is fixedly mounted on the upper end of each second linear motor 314. A plurality of first linear motors 312 are slidably mounted on the upper surface of the second movable plate 313. A first movable plate 311 is fixedly mounted on the upper end of each first linear motor 312, facilitating adjustment of the boiler header's position on the plane after placement. A first upright plate 302 is fixedly mounted on one side of the upper surface of the first movable plate 311, and a second upright plate 307 is fixedly mounted on the other side of the upper surface of the first movable plate 311, facilitating clamping of the boiler header to be welded. A first fixing screw is threaded onto the upper end of the first upright plate 302. A first telescopic rod 303 is rotatably mounted on the middle position of the side of the first upright plate 302. A first clamp 304 is fixedly connected to the end of the first telescopic rod 303 away from the first upright plate 302, so that the user can fix and clamp the boiler header by adjusting the length of the first telescopic rod 303. A second fixing knob 306 is threaded on the upper end of the second upright plate 307. A motor box 309 is fixedly mounted on the side of the second upright plate 307. A servo motor 310 is fixedly mounted inside the motor box 309. The output end of the servo motor 310 passes through the motor box 309 and through the second upright plate 307 and is fixedly mounted with a second clamp 305. A data transceiver 308 is fixedly mounted on the upper end of the motor box 309, so that the user can adjust the angle of the fixed boiler header.

[0029] The base mechanism 5 includes a lower support plate 503. Anti-slip pads 501 are fixedly installed at the four corners of the bottom surface of the lower support plate 503. Several insertion holes 502 are opened on the front of the lower support plate 503 to facilitate the user to place and use the device as a whole. The second lifting cylinder 4 is fixed on the lower support plate 503.

[0030] refer to Figure 3 , Figure 4 and Figure 7The support mechanism 6 includes two counterweight boxes 607. A damping shaft 603 is rotatably mounted on the upper end of each counterweight box 607. A second telescopic rod 602 is fixedly mounted at the middle position of each damping shaft 603. A support block 605 is fixedly connected to the upper end of each second telescopic rod 602. A slot 610 is provided on the support block 605. One end of the support plate 606 is engaged in the slot 610 on one counterweight box 607, and the other end of the support plate 606 is engaged in the slot 610 on the other counterweight box 607. This facilitates the user's daily assembly and storage of the support mechanism 6, enabling the support mechanism 6 to support the boiler header that needs to be welded, and improving the overall safety of the equipment.

[0031] The upper surface of the counterweight box 607 is provided with a placement slot 604 and a take-out slot 601. The placement slot 604 and the take-out slot 601 are connected. A handle 608 is fixedly provided on the outer wall of the counterweight box 607. A post 609 is fixedly provided at the bottom of the back of the counterweight box 607, which makes it convenient for the user to fold and store the support mechanism 6 and to combine and fix the support mechanism 6 and the device as a whole for use.

[0032] It should also be noted that the first movable plate 311, the second movable plate 313, and the support platform 315 are all provided with through holes in the middle for the support mechanism 6 to pass through.

[0033] The control mechanism 7 includes a connecting plate 705. One end of the connecting plate 705 is fixed to the end face of the lower support plate 503, and the other end of the connecting plate 705 is connected to the lower end of the third telescopic rod 704. The upper end of the third telescopic rod 704 is fixedly connected to a control box 701. The front of the control box 701 is fixedly provided with an LCD screen 702 and several control buttons 703, which facilitates the user to control and adjust the overall working status of the device.

[0034] The specific usage process of this invention is as follows:

[0035] The user first controls the first lifting cylinder 2 via the control mechanism 7 to adjust the fixing mechanism 3 to a suitable position, and then controls the second lifting cylinder 4 via the control mechanism 7 to adjust the positioning mechanism 1 to a suitable position. The distance between the two clamping blocks 106 is adjusted to clamp and fix the pipe to be welded using the clamping blocks 106. After fixing, the two clamping blocks 106 are secured with fixing bolts 105. The laser emitter 101 is then turned on to emit laser light from above the pipe, ensuring the pipe's verticality. The two support mechanisms 6 are removed via the handle 608, the second telescopic rod 602 is retracted to its lowest position, and the two insertion posts 609 are inserted into the insertion holes 502. Assemble the support plate 606 and support block 605, place the boiler header to be welded on the surface of the support plate 606, adjust the second lifting cylinder 4 to a suitable height, transfer the boiler header to be welded between the first clamp 304 and the second clamp 305, clamp the boiler header with the first telescopic rod 303, adjust the rotation of the servo motor 310 with the control mechanism 7, adjust the position of the first linear motor 312 and the second linear motor 314 with the control mechanism 7, align the welding part with the falling laser point, retract the second lifting cylinder 4, align the pipe to be welded with the boiler header, and perform welding. After welding is completed, the entire device can be removed.

[0036] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention.

Claims

1. A welding fixture for a boiler header, characterized in that, The system includes a first lifting cylinder (2), a second lifting cylinder (4), and a base mechanism (5). The bottom of the second lifting cylinder (4) is located at the top of the base mechanism (5), and the top of the second lifting cylinder (4) is connected to a fixing mechanism (3). The bottom of the first lifting cylinder (2) is located at the top of the fixing mechanism (3), and the top of the first lifting cylinder (2) is connected to a positioning mechanism (1). A support mechanism (6) is located in the middle of the upper surface of the base mechanism (5), and a laser emitter (101) is located on the positioning mechanism (1). A control mechanism (7) is fixedly connected to the end face of the base mechanism (5), and the control mechanism (7) is connected to the laser emitter (101), the first lifting cylinder (2), the second lifting cylinder (4), and the fixing mechanism (3). The positioning mechanism (1) includes an upper support plate (104), which is connected to the upper end of the first lifting cylinder (2). The upper surface of the upper support plate (104) is provided with several mounting holes (103), and the bottom surface of the upper support plate (104) is provided with several sliding grooves (102). The emitting end of the laser emitter (101) is inserted into the mounting hole (103), and the laser emitted by the laser emitter (101) can pass through the mounting hole (103). The upper end of the clamping block (106) is provided with a slider (107), which is located in the sliding groove (102). The two clamping blocks (106) form a pair, and the fixing bolt (105) passes through the clamping block (106) and the slider (107) and contacts the inner wall of the sliding groove (102). The fixing mechanism (3) includes a support platform (315), a first lifting cylinder (2) is set on the support platform (315), the upper end of the second lifting cylinder (4) is fixed to the bottom of the support platform (315), a plurality of second linear motors (314) are slidably arranged on the upper surface of the support platform (315), a second moving plate (313) is fixedly arranged on the upper end of the second linear motors (314), a plurality of first linear motors (312) are slidably arranged on the upper surface of the second moving plate (313), a first moving plate (311) is fixedly arranged on the upper end of the first linear motors (312), a clamping component is provided on the first moving plate (311), and the control mechanism (7) is connected to the first linear motors (312) and the second linear motors (314). The clamping component includes a first upright plate (302), which is disposed on one side of the upper surface of the first movable plate (311). A second upright plate (307) is fixedly disposed on the other side of the upper surface of the first movable plate (311). A first telescopic rod (303) is disposed on the side of the first upright plate (302). A first clamp (304) is fixedly connected to one end of the first telescopic rod (303) away from the first upright plate (302). A motor housing (309) is fixedly disposed on the side of the second upright plate (307). A servo motor (310) is fixedly disposed inside the motor housing (309). The output end of the servo motor (310) passes through the motor housing (309) and through the second upright plate (307) and is fixedly disposed on a second clamp (305). The control mechanism (7) is connected to the servo motor (310) and the first telescopic rod (303). The base mechanism (5) includes a lower support plate (503), and anti-slip pads (501) are fixedly installed at the four corners of the bottom surface of the lower support plate (503). The second lifting cylinder (4) and the support mechanism (6) are fixed on the lower support plate (503). The support mechanism (6) includes two counterweight boxes (607). The upper ends of the two counterweight boxes (607) are rotatably equipped with damping shafts (603). A second telescopic rod (602) is provided at the middle position of the damping shafts (603). The upper end of the second telescopic rod (602) is connected to a support block (605). A slot (610) is provided on the support block (605). One end of the support plate (606) is engaged in the slot (610) on one counterweight box (607), and the other end of the support plate (606) is engaged in the slot (610) on the other counterweight box (607). The control mechanism (7) includes a connecting plate (705), one end of which is fixed to the end face of the lower support plate (503), and the other end of which is connected to the lower end of the third telescopic rod (704). The upper end of the third telescopic rod (704) is fixedly connected to a control box (701).

2. The welding fixture for boiler headers according to claim 1, characterized in that, The front of the control box (701) is equipped with an LCD screen (702) and several control buttons (703), which are connected to the control box (701).

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