An efficient welding method for the top beam of a hydraulic support

Abstract

This invention provides an efficient welding method for the top beam of a hydraulic support, comprising the following steps: Step 1) Part blanking: Using plasma or laser cutting, all parts are blanked to reduce the allowance for pre-drilled holes; Step 2) Component welding: The outer main rib assembly and the inner main rib assembly are assembled; Step 3) Boring holes in the outer main rib assembly and the balance ear plate assembly: The outer arc contour position of the outer main rib assembly, close to the top hinge hole, is used as the reference for positioning; Step 4) Overall welding: An assembly platform is set up and a positioning plate is determined. Welding is performed using the positioning plate and the determined positioning reference as a unified reference. This efficient welding method for the top beam of the hydraulic support eliminates the pre-boring process by unifying the reference and simplifies the process and improves assembly efficiency by relying on shape positioning and other means.

Description

Technical Field

[0001] This invention relates to the field of hydraulic support technology, and more specifically, to a high-efficiency welding method for the top beam of a hydraulic support. Background Technology

[0002] Hydraulic supports, as the main support equipment in fully mechanized coal mining equipment, are customized products characterized by their large size and weight, small batch production, diverse types, harsh service conditions, and numerous box-type welded structures. The top beam is the main structural component of the hydraulic support, and together with the shield beam and base, they are known as the "three major components" of the hydraulic support. It consists of external main reinforcement components, internal main reinforcement components, balance ear plates, top plate, internal stiffening plates, ear plates, cover plates, and other components.

[0003] like Figure 1 As shown, during the manufacturing process of the top beam, the hinge holes of the inner main reinforcement assembly 2, the outer main reinforcement assembly 1, and their reinforcing plates are pre-drilled with a 23mm allowance, and the sleeve holes are pre-drilled with a 10mm allowance. During the pre-boring of the components, the hinge holes are pre-bored to a 13mm allowance, and the sleeve holes are also pre-bored. During assembly, the assembly mandrel 6 is used to assemble the components by passing the mandrel through the hinge holes to ensure assembly accuracy. During the subsequent overall boring, the components need to be repositioned and bored again to meet the coaxiality requirements.

[0004] The specific process of traditional manufacturing is as follows:

[0005] When using flame cutting for blanking, leave a 20-25mm allowance for the hinge holes of the main ribs and reinforcing plates, and a 10mm allowance for the sleeve holes;

[0006] Assemble the main ribs and reinforcing plates into a main rib assembly. On a boring machine, bore the hinge holes of the main rib assembly to a margin of 13-15mm. Bor the sleeve holes directly to the dimensions shown in the drawing. Bor the hinge holes of the balance ear plate assembly to the dimensions shown in the drawing.

[0007] First, assemble the top plate on the assembly platform. Then, use the splicing shaft to position and assemble the main ribs through the hinge hole at the top cover hinge end. Use the jig to assemble the balance ear plate to ensure that the center distance between the top cover hinge hole and the balance ear plate machining hole is ±1mm.

[0008] After assembly and welding are completed, the hinge holes are bored to the dimensions shown in the drawing.

[0009] With the increasing speed of hydraulic support delivery, the above-mentioned pre-boring hinge hole production method has many steps, requiring pre-boring of the hinge holes of the main rib assembly. The boring allowance is large, resulting in low production efficiency. At the same time, the assembly is difficult, requiring the insertion of an assembly mandrel, which also results in low assembly efficiency. It can no longer meet production needs.

[0010] In order to solve the above problems, people have been seeking an ideal technological solution. Summary of the Invention

[0011] The purpose of this invention is to address the shortcomings of existing technologies by providing a highly efficient welding method for hydraulic support top beams that simplifies the process and improves assembly efficiency by using a unified benchmark, eliminating the pre-boring process, and relying on shape positioning and other means.

[0012] To achieve the above objectives, the technical solution adopted by the present invention is: a high-efficiency welding method for the top beam of a hydraulic support, comprising the following steps:

[0013] Step 1) Part cutting:

[0014] All parts are cut using plasma or laser cutting. The hinge holes of the outer main ribs and their reinforcing plates are reserved with a first allowance, and the sleeve holes are reserved with a first allowance. The hinge holes of the inner main ribs and their reinforcing plates are reserved with a first allowance, and the sleeve holes are cut into holes that are 3mm larger than the nominal diameter of the sleeve.

[0015] Step 2) Component welding:

[0016] Draw the assembly position lines of each part on the outer main rib and the inner main rib, assemble the corresponding parts to form the outer main rib assembly and the inner main rib assembly, and perform tack welding reinforcement. After tack welding, the outer contour of each part avoids the arc position at the front end of the outer main rib and the inner main rib.

[0017] Step 3) Boring the outer main rib assembly and the balance ear plate assembly:

[0018] Set up a boring machine, and use the outer arc of the outer main rib assembly near the top of the hinge hole as a reference for positioning. Pre-bor the sleeve hole to the value required by the drawing, place the balance ear plate assembly on the boring machine, and bore the hinge hole to the value required by the drawing.

[0019] Step 4) Overall welding:

[0020] 4.1 Marking and positioning: Place each part on the assembly platform, which includes a support plate and a positioning plate perpendicular to the support plate;

[0021] 4.2 The outer arc contour of the inner main rib assembly and the outer main rib assembly near the top cover hinge hole is positioned by reference using the positioning plate, and then the sleeve is spliced ​​in the sleeve hole farthest from the hinge hole.

[0022] 4.3 Assemble the balance ear plate assembly: Assemble the balance ear plate assembly using a jig with one end being a through shaft and the other end being directly connected to the positioning plate. The through shaft is connected to the machining hole of the balance ear plate assembly to ensure that the distance tolerance between the machining hole of the balance ear plate assembly and the positioning plate is within ±1mm.

[0023] 4.4 The remaining internal stiffeners are assembled in sequence as required, reinforced with tack welding, and then welded by robot in one operation;

[0024] 4.5 Assemble the sleeves in the remaining sleeve holes. Using the positioning plate as a reference, assemble the top beam column socket between the inner and outer main reinforcement components. Ensure that the distance tolerance between the column socket core and the positioning plate is within ±1mm. Manually weld the welds that need to be welded.

[0025] 4.6 Assemble the cover plates in sequence as required, reinforce them with tack welding, and then perform secondary welding by robot;

[0026] 4.7 After all parts have been welded and completely cooled, the hinge holes on each main rib of the welded parts are bored as a whole, using the arc shape of the top hinge end as a reference, to achieve the required accuracy and coaxiality as specified in the drawing.

[0027] Based on the above, in step 1), the first allowance reserved for the hinge holes of the outer main reinforcement and its reinforcing plate is 15mm-20mm, the first allowance reserved for the sleeve hole is 10mm-15mm, and the first allowance reserved for the hinge holes of the inner main reinforcement and its reinforcing plate is 15mm-20mm. The value of the first allowance reserved for the hinge holes of the inner main reinforcement and its reinforcing plate is equal to the first allowance reserved for the hinge holes of the outer main reinforcement and the reinforcing plate.

[0028] Based on the above, in step 2), the locating weld length of the outer main rib assembly and the inner main rib assembly is 300mm-500mm, and the height is 3mm-5mm. The locating welds of the remaining parts are evenly distributed at intervals of 600mm-800mm. In step 2), the mounting plate including the hinge hole has three locating welds on each part.

[0029] This invention has outstanding substantive features and significant progress compared to the prior art. Specifically, this invention has the following advantages:

[0030] 1. The pre-boring process for the inner main reinforcement assembly has been eliminated, and the pre-boring process for the hinge holes in the outer main reinforcement assembly has been eliminated, reducing the boring allowance. The boring of the sleeve hole in the inner main reinforcement assembly has been eliminated and replaced by direct cutting during material preparation, which greatly simplifies the processing flow of the top beam main reinforcement assembly and improves production efficiency.

[0031] 2. The assembly efficiency of the top beam has been greatly improved. The previous method of positioning by using two splicing shafts at the front and back has been changed to positioning based on the outer contour of the front arc, which reduces the amount of manual assembly work and facilitates automated assembly.

[0032] 3. The manufacturing benchmark was unified. The assembly of the main ribs and the boring of the workpiece after welding were all based on the outer arc contour of the top hinge hole. An assembly platform with a positioning plate was configured. The above operations were carried out by relying on the positioning plate of the assembly platform, which achieved benchmark unification and helped to ensure the consistency of assembly and processing accuracy. Attached Figure Description

[0033] Figure 1This is a schematic diagram of the existing assembly structure of the hydraulic support top beam in the background technology.

[0034] Figure 2 This is a schematic diagram of the structure of the hydraulic support top beam in this invention.

[0035] Figure 3 This is one of the structural schematic diagrams of the outer main rib assembly in this invention.

[0036] Figure 4 This is the second structural schematic diagram of the outer main rib assembly in this invention.

[0037] Figure 5 This is a schematic diagram of the internal main rib assembly in this invention.

[0038] Figure 6 This is a schematic diagram of the structure of the balance ear plate assembly in this invention.

[0039] Figure 7 This is a structural diagram of the assembly process in this invention.

[0040] Figure 8 This is a schematic diagram of the assembly platform in this invention.

[0041] In the diagram: 1. Outer main reinforcement assembly; 2. Inner main reinforcement assembly; 3. Balance ear plate assembly; 4. Top cover hinge hole; 5. Sleeve hole furthest from the top cover hinge hole; 6. Assembly mandrel; 7. Outer main reinforcement; 8. Reinforcing rib; 9. Sleeve hole; 10. Hinge hole; 11. Column socket; 12. Positioning plate; 13. Assembly platform; 14. Inner main reinforcement; 15. Position of the outer arc contour at the foremost end of the outer main reinforcement. Detailed Implementation

[0042] The technical solution of the present invention will be further described in detail below through specific embodiments.

[0043] like Figures 2-8 As shown, an efficient welding method for the top beam of a hydraulic support includes the following steps:

[0044] Step 1) Part cutting:

[0045] All parts are cut using plasma or laser cutting. The first allowance for the outer main rib 7 and its reinforcing plate 8 hinge hole 10 is 15mm-20mm, and the first allowance for the sleeve hole 9 is 10mm-15mm.

[0046] The first allowance reserved for the inner main reinforcement 14 and its reinforcing plate hinge hole 10 is 15mm-20mm. The first allowance reserved for the inner main reinforcement and its reinforcing plate hinge hole is equal to the first allowance reserved for the outer main reinforcement and the reinforcing plate hinge hole. The sleeve hole 9 is cut into a hole that is 3mm larger than the nominal diameter of the sleeve.

[0047] Compared with traditional solutions, the allowance for each hole in the outer main rib, inner main rib, and reinforcing plate is significantly reduced. By utilizing the high precision of cutting, the pre-boring process can be directly omitted, reducing processing time and difficulty.

[0048] Step 2) Component welding:

[0049] Draw the assembly position lines of each part on the outer main rib 7 and the inner main rib 14, assemble the corresponding parts to form the outer main rib assembly 1 and the inner main rib assembly 2, and reinforce them with tack welding. The outer contour of each part after tack welding avoids the arc position at the front end of the outer main rib 7 and the inner main rib 14. The tack welding length in the outer main rib assembly 1 and the inner main rib assembly 2 is 300mm-500mm and the height is 3mm-5mm. The tack welding intervals of the remaining parts are evenly distributed at 600mm-800mm intervals, including the mounting plate of the hinge hole. Each part has three tack welding points.

[0050] In this step, ensure that the welded components do not interfere with the outer main rib 7 and the outer main rib 14 at their foremost arc positions, so as not to affect the determination of the positioning reference during the welding process and subsequent welding processing.

[0051] Step 3) Boring the outer main rib assembly 1 and the balance ear plate assembly 3:

[0052] Set up a boring machine, and use the outer arc contour position 15 of the outer main rib assembly, which is close to the top cover hinge hole 5, as the reference for positioning. Pre-bor the sleeve hole to the value required by the drawing, place the balance ear plate assembly on the boring machine, and bore the hinge hole to the value required by the drawing.

[0053] This step begins by determining the reference positioning position, using the outer arc contour position at the foremost end of the outer main reinforcement bar as the reference positioning.

[0054] Step 4) Overall welding:

[0055] 4.1 Marking and positioning: Place each part on the assembly platform 13. The assembly platform includes a support plate and a positioning plate 12 perpendicular to the support plate.

[0056] 4.2 The outer arc contour position 15 of the inner main rib assembly 2 and the outer main rib assembly 1, which is close to the top hinge hole 4, is positioned by reference using the positioning plate 12. Then, the sleeve is assembled in the sleeve hole farthest from the hinge hole. The position of the positioning plate 12 is the outer arc contour position 15 of the inner main rib assembly 2 and the outer main rib assembly 1, which is close to the top hinge hole 4. This achieves the standardization of the reference in the overall assembly process.

[0057] 4.3 Assemble the balance ear plate assembly 3: Assemble the balance ear plate assembly using a jig (not shown in the figure) with one end being a through shaft and the other end being directly connected to the positioning plate. The through shaft is connected to the machining hole of the balance ear plate assembly to ensure that the distance tolerance between the machining hole of the balance ear plate assembly and the positioning plate is within ±1mm.

[0058] 4.4 The remaining internal stiffeners are assembled in sequence as required, reinforced with tack welding, and then welded by robot in one operation;

[0059] 4.5 Assemble the sleeves in the remaining sleeve holes 9. Using the positioning plate as a reference, assemble the top beam column socket 11 between the inner and outer main reinforcement components, ensuring that the distance tolerance between the core of the column socket 11 and the positioning plate is within ±1mm, and perform manual welding on the welds that need to be welded.

[0060] 4.6 Assemble the cover plates in sequence as required, reinforce them with tack welding, and then perform secondary welding by robot;

[0061] 4.7 After all parts have been welded and completely cooled, the hinge holes on each main rib of the welded parts are bored as a whole, using the arc shape of the top hinge end as a reference, to achieve the required accuracy and coaxiality as specified in the drawing.

[0062] Compared to the traditional method of using the hinge hole of the top cover for positioning and using the traditional jig to assemble the balance ear plate, the positioning reference is the positioning plate from beginning to end, that is, the outer arc contour position of the foremost part of the inner main rib assembly and the outer main rib assembly near the hinge hole of the top cover, so the accuracy is higher.

[0063] 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 them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A highly efficient welding method for the top beam of a hydraulic support, characterized in that: The method comprises the following steps: Step 1) blanking of parts: Blanking of all parts is performed using plasma or laser cutting, wherein the outer main rib and its reinforcing plate hinge hole is reserved with a first allowance, and the sleeve hole is reserved with a first allowance; the inner main rib and its reinforcing plate hinge hole is reserved with a first allowance, and the sleeve hole is cut into a hole with a diameter of 3 mm larger than the nominal diameter of the sleeve; Step 2) assembly welding: Draw the assembly position line of each part on the outer main rib and the inner main rib, assemble the corresponding parts, form the outer main rib assembly and the inner main rib assembly, and perform positioning welding and reinforcement, wherein the outer contour of each part after positioning welding avoids the circular arc position of the front end of the outer main rib and the inner main rib; Step 3) boring of the outer main rib assembly and the balance ear plate assembly: Set up a boring machine, position the outer main rib assembly with the circular arc outer contour position of the front end of the outer main rib close to the top cover hinge hole as the reference, pre-bore the sleeve hole to the required value in the drawing, place the balance ear plate assembly on the boring machine, and bore the hinge hole to the required value in the drawing; Step 4) overall assembly welding: 4.1 Positioning by scribing, place each part on the assembly platform, which comprises a support plate and a positioning plate perpendicular to the support plate; 4.2 Control the circular arc outer contour position of the front end of the inner main rib assembly and the outer main rib assembly close to the top cover hinge hole to be positioned by the positioning plate as the reference, and then assemble the sleeve in the sleeve hole farthest from the hinge hole; 4.3 Assemble the balance ear plate assembly by using a jig with a shaft at one end and a direct connection with the positioning plate at the other end, wherein the shaft is connected with the processing hole of the balance ear plate assembly to ensure that the distance tolerance between the processing hole of the balance ear plate assembly and the positioning plate is within ±1 mm; 4.4 Assemble and position the remaining inner rib plates according to the requirements, and then perform robot welding; 4.5 Assemble the sleeves in the remaining sleeve holes, assemble the roof beam column nest between the inner and outer main rib assemblies with the positioning plate as the reference, ensure that the distance tolerance between the nest core and the positioning plate is within ±1 mm, and perform manual or robot welding on the welds that need to be welded; 4.6 Assemble and position the cover plates according to the requirements, and then perform robot welding; 4.7 After all parts are welded and completely cooled, use the circular arc shape of the top cover hinge end as the reference to bore the hinge holes on the main ribs of the parts as a whole, and bore the hinge holes to the required precision and coaxiality in the drawing.

2. The method for high efficient tailor-welding of hydraulic support roof timber according to claim 1, characterized in that: In step 1), the value of the first allowance reserved for the hinge hole of the outer main rib and its reinforcing plate is 15-20 mm.

3. The method of efficient tailor-welding of hydraulic support roof timber according to claim 1, characterized by the fact that: In step 1), the value of the first allowance reserved for the sleeve hole is 10-15 mm.

4. The method of efficient tailor-welding of hydraulic support roof timber according to claim 1, characterized by the fact that: In step 1), the value of the first allowance reserved for the hinge hole of the inner main rib and its reinforcing plate is 15-20 mm.

5. The high-efficiency tailor-welding method of hydraulic support roof timber according to claim 2 or 3, characterized in that: In step 1), the value of the first allowance reserved for the hinge hole of the inner main rib and its reinforcing plate is equal to the first allowance reserved for the hinge hole of the outer main rib and its reinforcing plate.

6. The method according to any one of claims 1-4, characterized in that the method is a high-efficiency tailor-welding method of hydraulic support roof beams. In step 2), the positioning welding length of the outer main rib assembly and the inner main rib assembly is 300-500 mm, and the height is 3-5 mm, and the positioning welding interval of the remaining parts is 600-800 mm.

7. The method for high efficient tailor-welding of hydraulic support roof timber according to claim 6, characterized in that: In step 2), the paste plate containing the hinge hole is positioned and welded three times for each part.

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