An efficient welding method for hydraulic support shield beams

Abstract

This invention provides an efficient welding method for hydraulic support shield beams, comprising the following steps: Step 1) Part blanking: Using a plasma or laser cutting machine, all parts are blanked, reducing the pre-boring process due to improved blanking accuracy; Step 2) Component welding: Welding to form the outer main rib assembly, inner main rib assembly, and hinged ear plate assembly; Step 3) Boring the sleeve holes of the outer main rib assembly: Using a positioning datum as the reference; Step 4) Overall welding: Welding and assembling using the outer contour as a unified datum to improve accuracy. This efficient welding method for hydraulic support shield beams has the advantages of unified datum, simplified boring process, and improved processing efficiency.

Description

Technical Field

[0001] This invention relates to the field of hydraulic support technology, and more specifically, to a highly efficient welding method for hydraulic support shield beams. 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 shield beam is a major structural component of the hydraulic support, and together with the top beam and base, they are known as the "three major components" of the hydraulic support. It consists of external main reinforcement assemblies, internal main reinforcement assemblies, hinged ear plates, balance ear plates, top plate, internal stiffening plates, ear plates, and cover plates.

[0003] Because hydraulic supports come in many varieties, with varying shapes, structures, and box dimensions, assembly is difficult. Therefore, it's challenging to use specialized assembly jigs or automated equipment during manufacturing. Currently, the assembly of shield beams is primarily done manually, resulting in low efficiency. For example... Figure 1 As shown, currently, during the manufacturing process of the shield beam, the hinge holes of the inner main reinforcement, outer main reinforcement, and their reinforcing plates are pre-drilled with a margin of 20-25mm when the material is cut, and the sleeve holes are all pre-drilled with a margin of more than 10mm. During the pre-boring of the components, the hinge holes are pre-bored to a margin of 13-15mm based on the front end shape of the components, and the sleeve holes are also bored. During assembly, two assembly mandrels are used to assemble the components by passing through the front and rear hinge holes to ensure assembly accuracy, and the assembly is carried out based on the coaxiality of the assembly mandrels. During the subsequent overall boring, the circular arc shape of the top shield hinge hole is used as the reference for positioning, and the boring is carried out again to meet the coaxiality requirements.

[0004] Problems with traditional assembly methods:

[0005] 1. The assembly process is complicated. The hinge hole requires two splicing shafts to be inserted from the front and back, which results in high labor intensity for personnel. Moreover, due to the deformation of the workpiece during welding, the two splicing shafts cannot be inserted at the same time.

[0006] 2. The large allowance for boring holes and the increased number of boring holes restrict the overall assembly efficiency of the shield beam;

[0007] 3. Inconsistent boring and assembly standards resulted in poor consistency of the shield beams, which affected the robotic automatic welding of the shield beam workpieces.

[0008] With the increase in order volume and cost optimization, the above-mentioned pre-bored articulated hole production method can no longer meet production needs due to its low efficiency and high cost.

[0009] For example, the patent with publication number CN 106956085 B uses a method of dividing the protective beam into two box-shaped sections, assembling and welding them separately, and then assembling them together. Although this method solves some of the problem of welding deformation of the main rib components, the overall assembly efficiency is still low and cannot meet the needs of large-scale production. In order to solve the above problems, people have been seeking an ideal technical solution. Summary of the Invention

[0010] The purpose of this invention is to address the shortcomings of existing technologies by providing a highly efficient welding method for hydraulic support shield beams that features unified benchmarks, simplified boring processes, and improved machining efficiency.

[0011] To achieve the above objectives, the technical solution adopted by this invention is: a highly efficient welding method for hydraulic support shield beams, comprising the following steps:

[0012] Step 1) Part cutting:

[0013] All parts are cut using a plasma or laser cutting machine. The hinge holes of the outer main ribs and their reinforcing plates are reserved with a set allowance, and the sleeve holes are reserved with a set allowance. The hinge holes of the inner main ribs and their reinforcing plates are reserved with a set allowance. The sleeve holes are cut to be 3mm larger than the nominal diameter of the sleeve. The sleeve holes in the hinge ear plate assembly are cut to be 15mm larger than the nominal diameter of the sleeve.

[0014] Step 2) Component welding:

[0015] Draw the assembly position lines of each part on the outer main rib and the inner main rib, assemble each part to form the outer main rib assembly and the inner main rib assembly. After each part is welded, it is necessary to avoid the frontmost arc position of the outer main rib and the inner main rib.

[0016] Draw the assembly position line of the patch plate on the hinge ear plate of the hinge ear plate assembly. Using the arc at the front end of the top cover hinge hole as a reference, assemble the patch plate to ensure that the arc shape of the hinge ear plate and the patch plate are consistent. The edge of the patch plate at the arc is 1-2mm lower than the hinge ear plate and is reinforced by tack welding. No tack welding is performed at the arc at the front end of the top cover hinge hole.

[0017] Step 3) Boring the sleeve hole of the outer main reinforcement assembly:

[0018] Place the welded outer main rib assembly on a special boring machine, and position it based on the leftmost end face of the outer main rib. Pre-bor the sleeve hole to the value required by the drawing.

[0019] Step 4) Overall welding:

[0020] 4.1 Marking and positioning: Place all components on a dedicated assembly platform, which is equipped with positioning plates perpendicular to the surface of the assembly platform;

[0021] 4.2 The inner main ribs and hinged ear plates are positioned and assembled by aligning the frontmost edge of the arc at the top hinge hole with the positioning plate at the front of the assembly platform.

[0022] 4.3 The outer main rib assembly is precisely positioned and assembled with the inner main rib assembly by means of the assembly mandrel, which is the sleeve hole machined by the boring machine at the farthest end from the top cover hinge hole, to ensure that the distance between the assembly mandrel and the positioning plate on the assembly platform is ±1mm of the drawing size;

[0023] 4.4 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 between the center of the machining hole of the balance ear plate assembly and the positioning plate of the assembly platform is ±1mm of the drawing size.

[0024] 4.5 Assemble the remaining internal stiffening plates in sequence as required, and reinforce them with tack welds, then perform a first welding; assemble the cover plate in sequence as required, reinforce it with tack welds, and then perform a second welding;

[0025] 4.6 Using the top hinge end arc as a reference, bore the hinge holes on each main rib of the welded workpiece as a whole, and bore the hinge holes to the accuracy and coaxiality required by the drawing.

[0026] Based on the above, in step 1), a 15mm-20mm allowance is reserved for the hinge holes of the outer main reinforcement and its reinforcing plate, a 10mm-15mm allowance is reserved for the sleeve holes of the outer main reinforcement, and a 15mm-20mm allowance is reserved for the hinge holes of the inner main reinforcement and its reinforcing plate. The allowance reserved for the hinge holes of the inner main reinforcement and its reinforcing plate is equal to the allowance reserved for the hinge holes of the outer main reinforcement and its reinforcing plate.

[0027] Based on the above, in step 2), each part of the outer main rib assembly and the inner main rib assembly is tack welded. The tack weld length is 300mm-500mm and the height is 3mm-5mm. This includes the mounting plate for the hinge hole. Each part is tack welded three times, avoiding the frontmost arc position of the inner and outer main rib assemblies. The tack welds of the remaining parts are evenly distributed at intervals of 600mm-800mm. The hinge ear plate and the mounting plate are reinforced by tack welds. The tack weld length is 300-500mm and the height is 3-5mm. The tack welds are evenly distributed at intervals of 600-800mm.

[0028] This invention has outstanding substantive features and significant progress compared to the prior art. Specifically, this invention has the following advantages:

[0029] 1. The processing flow of the main reinforcement of the shield beam has been optimized. Specifically, the boring process of the inner main reinforcement has been eliminated, and the pre-boring process of the hinge hole of the outer main reinforcement has been eliminated, which has greatly improved production efficiency.

[0030] 2. Assembly efficiency has been improved. The previous method of assembling by inserting two assembly shafts at the front and back has been changed to assembling the front end based on the outline and the rear end by inserting only the sleeve hole assembly shaft. This reduces the workload of manual assembly and is conducive to realizing automated assembly.

[0031] 3. The manufacturing benchmark was unified. The processes of boring the outer main rib, assembly, and boring the workpiece as a whole after welding are all based on the arc shape of one end of the top mask hinge hole, which realizes the benchmark unification and helps to ensure the overall accuracy of assembly. Attached Figure Description

[0032] Figure 1 This is a structural schematic diagram of the welding process of the hydraulic support shield beam in the background technology.

[0033] Figure 2 This is a schematic diagram of the efficient welding structure of the hydraulic support shield beam in this invention.

[0034] Figure 3 This is a schematic diagram of the structure of the outer main rib assembly in this invention.

[0035] Figure 4 This is a schematic diagram of the internal main rib assembly in this invention.

[0036] Figure 5 This is a schematic diagram of the hinged ear plate assembly in this invention.

[0037] Figure 6 This is a schematic diagram of the structure of the balance ear plate assembly in this invention.

[0038] Figure 7 This is a schematic diagram illustrating the efficient welding principle of the hydraulic support shield beam in this invention.

[0039] In the diagram: 1. Outer main reinforcement assembly; 2. Inner main reinforcement assembly; 3. Hinge plate assembly; 4. Balance plate assembly; 5. Top cover hinge hole; 6. Sleeve hole furthest from the top cover hinge hole; 7. Outer main reinforcement; 8. Sleeve hole; 9. Hinge hole; 10. Inner main reinforcement; 11. Positioning plate; 12. Assembly mandrel. Detailed Implementation

[0040] The technical solution of the present invention will be further described in detail below through specific embodiments.

[0041] like Figures 2-7 As shown, an efficient welding method for hydraulic support shield beams includes the following steps:

[0042] Step 1) Part cutting:

[0043] Use a plasma or laser cutting machine to cut all parts, with a 15mm-20mm allowance reserved for the hinge holes of the outer main rib 7 and its reinforcing plate, and a 10mm-15mm allowance reserved for the sleeve hole 8.

[0044] The inner main rib 10 and its reinforcing plate hinge holes are reserved with a margin of 15mm-20mm. The sleeve 8 holes are cut to be 3mm larger than the nominal diameter of the sleeve. The sleeve holes in the hinge ear plate assembly 3 are cut to be 15mm larger than the nominal diameter of the sleeve.

[0045] Normally, the allowance for the hinge holes of the inner main reinforcement 10 and its reinforcing plate is equal to the allowance for the hinge holes of the outer main reinforcement 7 and its reinforcing plate.

[0046] In this step, the boring process for the inner main ribs in the traditional welding process is eliminated, and the pre-boring process for the hinge holes of the outer main ribs is eliminated.

[0047] Step 2) Component welding:

[0048] Draw the assembly position lines of each part on the outer main rib 7 and the inner main rib 10, assemble each part to form the outer main rib assembly 1 and the inner main rib assembly 2, and reinforce them with tack welding. The tack welding length is 300mm-500mm and the height is 3mm-5mm, including the plate for the hinge hole 9. Each part is tack welded three times, avoiding the frontmost arc position of the inner and outer main rib assemblies, so as not to affect the accuracy of the positioning reference.

[0049] Draw the assembly position line of the patch plate on the hinge ear plate of the hinge ear plate assembly 3. Using the arc at the front end of the top mask hinge hole 5 as a reference, assemble the patch plate to ensure that the arc shape of the hinge ear plate and the patch plate is consistent. The edge of the patch plate at the arc is 1-2mm lower than the hinge ear plate. Reinforce it with tack welding. The tack welding length is 300-500mm, the height is 3-5mm, and the tack welding interval is 600-800mm evenly distributed. Do not perform tack welding at the arc at the front end of the top mask hinge hole. The purpose is to prevent the tack welding itself from interfering with the accuracy of the arc at the front end, such as the outline of the tack welding exceeding the arc outline.

[0050] Step 3) Boring the sleeve hole of the outer main reinforcement assembly:

[0051] Place the welded outer main rib assembly on a special boring machine, and position it based on the leftmost end face of the outer main rib. Pre-bor the sleeve hole to the value required by the drawing.

[0052] Step 4) Overall welding:

[0053] 4.1 Marking and positioning: Place all parts on a dedicated assembly platform. The assembly platform is equipped with a positioning plate 11 that is perpendicular to the surface of the assembly platform.

[0054] 4.2 The inner main rib 10 and the hinge ear plate are positioned and assembled by aligning the front end of the arc at the top hinge hole 5 with the positioning plate 11 at the front end of the assembly platform, thus determining the positioning reference for the entire welding process, namely the positioning plate 11.

[0055] 4.3 The outer main rib assembly is precisely positioned and assembled with the inner main rib assembly by means of the assembly mandrel, which is the sleeve hole machined by the boring machine at the farthest end from the top cover hinge hole, to ensure that the distance between the assembly mandrel and the positioning plate on the assembly platform is ±1mm of the drawing size;

[0056] 4.4 Assemble the balance ear plate assembly 4: 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 between the center of the machining hole of the balance ear plate assembly and the positioning plate of the assembly platform is ±1mm of the drawing size.

[0057] 4.5 Assemble the remaining internal stiffening plates in sequence as required, and reinforce them with tack welds, then perform a first welding; assemble the cover plate in sequence as required, reinforce it with tack welds, and then perform a second welding;

[0058] 4.6 Using the top hinge end arc as a reference, bore the hinge holes on each main rib of the welded workpiece as a whole, and bore the hinge holes to the accuracy and coaxiality required by the drawing.

[0059] Compared to the traditional method of assembling by using two front and rear axles, the positioning reference is always the positioning plate, which is the outer arc of the frontmost part of the top cover hinge hole, thus achieving higher precision.

[0060] 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 hydraulic support shield beams, characterized in that: The method comprises the following steps: Step 1) blanking of parts: All parts are blanked by using a plasma or laser cutting machine, wherein the outer main rib and its reinforcing plate hinge hole is reserved with a set margin, the sleeve hole is reserved with a set margin; the inner main rib and its reinforcing plate hinge hole is reserved with a set margin, the sleeve hole is cut into a hole with a diameter of 3 mm larger than the nominal diameter of the sleeve, the sleeve hole in the hinge ear plate assembly is cut into a hole with a diameter of 15 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 each part to form an outer main rib assembly and an inner main rib assembly, wherein each part needs to avoid the front end arc position of the outer main rib and the inner main rib after assembly welding; Draw the assembly position line of the plate on the hinge ear plate of the hinge ear plate assembly, take the arc at the front end of the hinge hole as a reference, assemble the plate, ensure that the arcs of the hinge ear plate and the plate are assembled consistently, and the edge of the plate at the arc is 1-2 mm lower than the hinge ear plate, and perform positioning welding reinforcement, and the arc at the front end of the hinge hole is not subjected to positioning welding reinforcement; Step 3) sleeve hole boring of the outer main rib assembly: Place the assembled outer main rib assembly on a special boring machine, position it by taking the end face of the leftmost end of the outer main rib as a reference, and pre-bore the sleeve hole to the required value in the drawing; Step 4) overall assembly welding: 4.1 marking and positioning, place all parts on a special assembly platform, and the assembly platform is provided with a positioning plate perpendicular to the surface of the assembly platform; 4.2 the inner main rib and the hinge ear plate are positioned and assembled by abutting the positioning plate at the front end of the arc at the top of the hinge hole on the assembly platform; 4.3 the outer main rib assembly is positioned and assembled by penetrating the farthest end of the sleeve hole processed by the boring machine into the inner main rib assembly through the assembly mandrel, to ensure that the distance between the assembly mandrel and the positioning plate on the assembly platform is within ±1 mm of the drawing size; 4.4 balance ear plate assembly: the balance ear plate assembly is assembled by using a jig with one end penetrating the shaft and the other end directly connected to the positioning plate, the penetrating shaft is connected to the processing hole of the balance ear plate assembly, and the distance between the center of the processing hole of the balance ear plate assembly and the positioning plate on the assembly platform is within ±1 mm of the drawing size; 4.5 the remaining internal rib plates are sequentially assembled according to the requirements, and are subjected to positioning welding reinforcement, and then are subjected to primary welding; the cover plates are sequentially assembled according to the requirements, and are subjected to positioning welding reinforcement, and then are subjected to secondary welding; 4.6 the hinge holes on each main rib of the welded workpiece are bored as a whole by taking the arc at the hinge end as a reference, and the hinge holes are bored to the required precision and coaxiality in the drawing.

2. The efficient tailor-welding method of hydraulic support canopy according to claim 1, characterized in that: In step 1), the outer main rib and its reinforcing plate hinge hole is reserved with a margin of 15-20 mm.

3. The high-efficiency tailor-welding method of hydraulic support canopy according to claim 2, characterized in that: In step 1), the sleeve hole of the outer main rib is reserved with a margin of 10-15 mm.

4. The high-efficiency tailor-welding method of hydraulic support canopy according to claim 2, characterized in that: In step 1), the inner main rib and its reinforcing plate hinge hole is reserved with a margin of 15-20 mm.

5. The efficient tailor-welding method of hydraulic support canopy according to claim 4, characterized in that: In step 1), the hinge hole reserved margin of the inner main rib and its reinforcing plate is equal to the hinge hole reserved margin of the outer main rib and its reinforcing plate.

6. The high-efficiency tailor-welding method of the hydraulic support canopy beam according to any one of claims 1-5, characterized in that: In step 2), the parts of the outer main reinforcement assembly and the inner main reinforcement assembly are positionally welded, the length of the positionally welded part is 300-500 mm, and the height is 3-5 mm, wherein the pasting plate containing the hinged hole is positionally welded three times for each part, avoiding the position of the front end arc of the inner and outer main reinforcement assemblies, and the rest of the parts are positionally welded at intervals of 600-800 mm.

7. The method of efficient tailor-welding of hydraulic support canopy as claimed in claim 1 wherein: In step 2), the hinged ear plate and the pasting plate are positionally welded and reinforced, the length of the positionally welded part is 300-500 mm, the height is 3-5 mm, and the positionally welded parts are evenly distributed at intervals of 600-800 mm.

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