Methods and integrated devices for manufacturing high-strength anchors

Abstract

This invention relates to a method and integrated device for manufacturing high-strength anchors. The method includes the following steps: (1) processing steel raw materials into a cylindrical shape to form a raw material block, and heating the raw material block at high temperature to obtain red-hot material; (2) hammering the red-hot material into block segments under the force of a press to obtain block segment material; (3) placing the block segment material into a forming mold cavity, and under the force of a press, pressing the upper and lower molds of the mold cavity together, causing the block segment material to collapse vertically and fill the inner cavity of the forming mold cavity radially until the mold cavity is closed to obtain a formed material; (4) punching the formed material in one go under the force of a press equipped with a punch to form several expanded conical holes to obtain punched material; (5) shot blasting the punched material to remove the oxide scale on the surface of the punched material, and then processing it on a lathe according to the dimensions required by the product to obtain a semi-finished product; (6) using a press with a conical head at room temperature to shape the through holes of the semi-finished product to obtain the anchor product.

Description

Technical Field

[0001] This invention belongs to the technical field of anchor manufacturing equipment, specifically relating to a method and integrated device for manufacturing high-strength anchors. Background Technology

[0002] Anchors are permanent anchoring devices used in prestressed concrete. In post-tensioned structures or components, they are anchoring tools used to maintain the tension of prestressing tendons and transfer it into the concrete. Anchors are a relatively mature building component, widely used, and suitable for industrial mass production. Anchors are made from rod-shaped metal raw materials, which are heated, forged, and then have holes drilled. Currently, anchor production mainly involves raw material forging, machining, heat treatment, and surface treatment. However, current anchor products generally suffer from low strength and poor toughness, which is related to the internal structure and defects of the metal material caused by the stress pattern during processing. Furthermore, current anchor production equipment is decentralized, with various forging equipment, hole-making equipment, heating equipment, shot blasting machines, lathes, etc., arranged according to factory space. These machines are interconnected by conveyor belts, resulting in low automation, inefficient site layout, large footprint, and increased probability of material jamming, falling, and misalignment during long-distance transport. Summary of the Invention

[0003] To address the above problems, the present invention provides a method and integrated apparatus for manufacturing high-strength anchors. In a first aspect, the method for manufacturing high-strength anchors includes the following steps:

[0004] (1) The steel raw material is processed into a cylindrical shape to become a raw material block, and the raw material block is heated at high temperature to obtain red-hot material;

[0005] (2) The red-hot material is hammered into sections under the force of a press to obtain the section material;

[0006] (3) Place the block material into the forming mold cavity. Under the force of the press, the upper and lower molds of the mold cavity are pressed together. The block material collapses vertically and fills the inner cavity of the forming mold cavity radially until the mold cavity is closed, thus obtaining the forming material.

[0007] (4) The molding material is punched in one go under the force of a press equipped with a punch to form several expanded conical holes, thus obtaining punched material;

[0008] (5) The punched material is shot blasted to remove the oxide scale on the surface of the punched material, and then processed by a lathe according to the dimensions required by the product to obtain a semi-finished product.

[0009] (6) At room temperature, the through hole of the semi-finished product is shaped using a press with a cone head to obtain the anchor product.

[0010] Optionally, the heating temperature in step (1) is 1050-1150℃ and the heating time is 1-10min.

[0011] Optionally, the pressure of the press in steps (2), (3) and (4) is 5000-6000KN.

[0012] Optionally, in step (3), the pier section is placed into the forming mold cavity, and the gap formed after the upper mold and the lower mold are closed is 0.1-0.8cm.

[0013] Optionally, in step (4), the bottom end of the punch is cylindrical and the top end is an outwardly expanding cone. After the punch is pressed into the blank, it forms an expanded cone hole with one end larger and the other end smaller.

[0014] The shot blasting time in step (5) depends on the surface oxidation of the punching material.

[0015] Optionally, in step (6), the pressure of the press is 5000-6000KN, the shape of the cone is the same as that of the expanding cone hole, and the size is slightly larger than the inner diameter of the expanding cone hole. The press presses down so that the cone is pressed into the expanding cone hole, strengthens the deformation, and improves the surface hardness, wear resistance and fatigue toughness of the expanding cone hole.

[0016] The vertical deformation of the expanded tapered hole is 0.4-0.5 mm.

[0017] Secondly, the integrated device includes a heating unit and a polishing unit. The heating unit is located above the polishing unit. The outer sides of the polishing unit are respectively provided with a block-forming unit, a forming unit, a punching unit and a cooling unit in a clockwise or counterclockwise direction.

[0018] The heating unit consists of four sections connected end to end to form a square heating chamber. The temperature of the heating chamber gradually increases in a clockwise or counterclockwise direction. The raw material is input from the end of the lowest temperature heating chamber and is heated in sequence through each heating chamber. It is then output from the highest temperature heating chamber to complete the heating process.

[0019] The pier section unit includes a first press hammer, the forming unit includes a second press hammer and an openable mold, the punching unit includes a third press hammer with a punch on the lower surface for punching, and the cooling unit includes a cooling spray pipe and a cooling conveyor belt from top to bottom.

[0020] The integrated device for manufacturing high-strength anchors described in this invention adopts an upper and lower structure. A heating unit is placed at the top, and a polishing unit is located at the bottom, making full use of space. Since heat mainly rises upwards, its impact on the lower units is minimal. Polishing requires a relatively large and deep independent space. This invention utilizes the four side walls of the polishing unit, also not far from the heating unit, to respectively arrange a segmenting unit, a forming unit, a punching unit, and a cooling unit clockwise or counterclockwise. This allows the heated raw material to pass through the segmenting unit, forming unit, punching unit, and cooling unit sequentially along the outer layer of the polishing unit, completing the segmenting, molding, punching, and cooling processes, before entering the polishing unit for grinding to obtain the anchor product. This invention makes rational use of space, conforms to the processing steps of the raw material, and makes full use of space. The raw material used in this field is a cylinder.

[0021] Optionally, the heating unit includes four heating chambers and an insulation sleeve wrapped around the outside of the heating chambers. The heating unit is a hollow ring that forms a square shape.

[0022] The first heating chamber, the second heating chamber, the third heating chamber, and the fourth heating chamber are arranged in a counterclockwise direction and connected end to end to form an internally continuous heating channel; heating and temperature control devices are respectively provided on the outside of the first heating chamber, the second heating chamber, the third heating chamber, and the fourth heating chamber, so that the temperature of the four heating chambers gradually increases;

[0023] The first heating chamber has a raw material inlet at the beginning and the fourth heating chamber has a heating material outlet at the end.

[0024] Optionally, a first transition portion is provided at the connection between the end of the first heating chamber and the beginning of the second heating chamber, a second transition portion is provided at the connection between the end of the second heating chamber and the beginning of the third heating chamber, and a third transition portion is provided at the connection between the end of the third heating chamber and the beginning of the fourth heating chamber. Each of the above transition portions is used to adjust the moving direction of the raw material block transmitted from the low-temperature side heating chamber, so that it can enter the connected high-temperature side heating chamber.

[0025] Optionally, the first adapter includes a first gripper, a first slide bar, and a first guide rail. The first guide rail is located between the end of the first heating cavity and the beginning of the second heating cavity. The first guide rail is an arc shape protruding outward from the heating cavity and is horizontal. The end of the first guide rail near the first heating cavity is provided with a straight section of the guide rail parallel to the second heating cavity, and the straight section of the guide rail points to the beginning of the second heating cavity.

[0026] The first gripper is slidably connected to the first guide rail via the first slide rod and slides along the first guide rail. The two handles of the first gripper face the outside of the heating unit, and the two jaws point to the inside of the heating unit. The jaws are used to clamp the raw material block that moves between the first heating chamber and the second heating chamber, and then drive the raw material block to rotate 90° clockwise, so that it is parallel to the second heating chamber. The first gripper and the first slide rod move along the straight section of the guide rail toward the second heating chamber, thereby pushing the raw material block into the second heating chamber.

[0027] Optionally, the end of the fourth heating chamber is provided with a vertical hot material conveyor belt for transporting the raw material block heated by the heating unit to the block segment unit;

[0028] Several hot material receiving parts are evenly arranged on the hot material conveyor belt. The hot material receiving parts are connected to the hot material conveyor belt through a rotating seat. The hot material receiving parts include a first plate and a second plate that are perpendicular to each other. The hot material receiving parts can rotate under the drive of the rotating seat, which facilitates the transportation of the material discharged from the heating unit to the pier unit.

[0029] Optionally, the pier segment unit includes a first press hammer, a first robotic arm, and a pier segment platform. The first robotic arm holds the red-hot raw material pier delivered by the horizontal conveyor belt and then moves it to the pier segment platform. The pier head of the first press hammer falls and strikes the thick, vertical red-hot raw material pier.

[0030] Optionally, the forming unit includes a second press hammer, an openable mold, and a second robotic arm. The second robotic arm grips the raw material block that has passed through the block section and is sent by the horizontal conveyor belt, and vertically places it into the open mold. The block head of the second press hammer falls and strikes the mold until the mold is completely closed.

[0031] Optionally, the punching unit includes a third press hammer, a third robot arm, and a punching die cavity. The lower surface of the third press hammer is provided with several embedded combination punches, the bottom end of which is columnar and used for punching.

[0032] Optionally, the cooling unit has a cooling spray pipe with several nozzles evenly distributed for spraying cooling water downwards to cool the raw material block after punching; the cooling conveyor belt includes several inclined sections from top to bottom, with the inclination directions of two adjacent sections being opposite and connected end to end to form several zigzag patterns.

[0033] Optionally, each strip has a horizontal pushing section at its bottom, and the pushing section moves in the same direction as the strip it belongs to. When the raw material block moves to the top of the lower strip, it is pushed onto the pushing section of the upper strip and changes its direction of movement on the pushing section, with the original front end becoming the rear end and the original rear end becoming the front end, continuing to move along the upper strip.

[0034] Optionally, a drying hopper is also hung on the outer surface of the polishing unit where the cooling unit is located, for collecting the cooled workpieces, drying them, and then pouring them into the polishing unit.

[0035] Drying fans are installed above and below the drying hopper to blow air into the drying hopper.

[0036] Further optionally, the drying hopper is a cube, including an upper frame and a lower frame. The top and bottom surfaces of the upper frame are open, and it only has mesh sides around the perimeter. The top surface of the lower frame is open, and it has a mesh bottom surface and mesh sides around the perimeter. Hooks are provided on the four top edges of the lower frame.

[0037] The lower slide frame is slidably connected to the outside of the upper frame. By adjusting the hooks to hang on different positions of the upper frame, the total length of the drying hopper can be adjusted.

[0038] Traditional anchor manufacturing processes require multiple turning operations, chamfering, and adjustments to the through-hole dimensions. The method and integrated device for manufacturing high-strength anchors described in this invention can produce anchor products in a single piece. The punch and cone can form through holes with compliant dimensions and high precision, eliminating the need for repeated machining. Furthermore, the impact of the press hammers on the raw material block by the block unit and forming unit, along with the deformation restriction of the raw material block by the mold and punching die cavity, subjectes the metal material to unidirectional, bidirectional, and multidirectional tensile and compressive forces. This eliminates and improves internal defects during the metal smelting and rolling process, thereby refining the internal structure of the metal and improving its grain size. This significantly improves the overall mechanical properties of the anchor product, significantly enhancing its strength, toughness, and plasticity, thus more effectively meeting the comprehensive performance requirements of various application scenarios. Attached Figure Description

[0039] Figure 1 A top view of an integrated device for manufacturing high-strength anchors;

[0040] Figure 2 for Figure 1 A three-dimensional view (polishing unit omitted);

[0041] Figure 3 This is a schematic diagram of the interior of the heating chamber;

[0042] Figure 4 A side view of an integrated device for manufacturing high-strength anchors;

[0043] Figure 5 This is a schematic diagram of the drying hopper.

[0044] In the attached diagram, 1-Heating unit, 2-Polishing unit, 3-Building section unit, 4-Forming unit, 5-Punching unit, 6-Cooling unit, 7-Raw material block, 8-First press hammer, 9-Second press hammer, 10-Third press hammer, 11-Punch, 12-Cooling spray pipe, 13-Cooling conveyor belt, 14-Building section platform, 15-First heating chamber, 16-Second heating chamber, 17-Third heating chamber, 18-Fourth heating chamber, 19-Feeder, 20-First transfer part, 21- 22-Third transfer section, 23-First gripper, 24-Lower slide frame, 25-First guide rail, 26-Straight section guide rail, 27-Handle, 28-Gripper head, 29-Turntable, 30-Hot material conveyor belt, 31-Hot material receiving section, 32-Rotating seat, 33-First plate, 34-Second plate, 35-Push plate, 36-Horizontal conveyor belt, 37-Mold, 38-Punching lower die cavity, 39-Hook, 40-Separator belt, 41-Push section, 42-Drying hopper, 43-Upper frame. Detailed Implementation

[0045] This embodiment provides a method for manufacturing high-strength anchors, including the following steps:

[0046] (1) The steel raw material is processed into a cylindrical shape to become a raw material block, and the raw material block is heated at high temperature to obtain red-hot material;

[0047] (2) The red-hot material is hammered into sections under the force of a press to obtain the section material;

[0048] (3) Place the block material into the forming mold cavity. Under the force of the press, the upper and lower molds of the mold cavity are pressed together. The block material collapses vertically and fills the inner cavity of the forming mold cavity radially until the mold cavity is closed, thus obtaining the forming material.

[0049] (4) The molding material is punched in one go under the force of a press equipped with a punch to form several expanded conical holes, thus obtaining punched material;

[0050] (5) The punched material is shot blasted to remove the oxide scale on the surface of the punched material, and then processed by a lathe according to the dimensions required by the product to obtain a semi-finished product.

[0051] (6) At room temperature, the through hole of the semi-finished product is shaped using a press with a cone head to obtain the anchor product.

[0052] The heating temperature in step (1) is 1100℃ and the heating time is 6min.

[0053] The pressure of the press in steps (2), (3) and (4) is 5000KN.

[0054] In step (3), the pier section is placed into the forming mold cavity, and the gap formed after the upper mold and the lower mold are closed is 0.4cm.

[0055] In step (4), the bottom end of the punch is cylindrical and the top end is an outwardly expanding cone. After the punch is pressed into the blank, it forms an expanded cone hole with one end larger and the other end smaller.

[0056] The shot blasting process in step (5) takes 15 minutes.

[0057] In step (6), the pressure of the press is 5000KN, the shape of the cone is the same as that of the expanding cone hole, and the size is slightly larger than the inner diameter of the expanding cone hole. The press presses down so that the cone head is pressed into the expanding cone hole, which strengthens the deformation and improves the surface hardness, wear resistance and fatigue toughness of the expanding cone hole; the vertical deformation of the expanding cone hole is 0.4mm.

[0058] This embodiment provides an integrated device for manufacturing high-strength anchors, such as... Figures 1-5 As shown, it includes a heating unit 1 and a polishing unit 2. The heating unit 1 is located above the polishing unit 2. The outer sides of the polishing unit 2 are respectively provided with a block section unit 3, a forming unit 4, a punching unit 5 and a cooling unit 6 in a clockwise or counterclockwise direction.

[0059] Heating unit 1 includes four sections connected end to end to form a square heating chamber. The temperature of the heating chamber gradually increases in a clockwise or counterclockwise direction. The raw material dart 7 is input from the end of the heating chamber with the lowest temperature, and is heated by passing through each heating chamber in sequence. It is then output from the heating chamber with the highest temperature to complete the heating process.

[0060] The pier unit 3 includes a first press hammer 8, the forming unit 4 includes a second press hammer 9 and an openable mold 37, the punching unit 5 includes a third press hammer 10, and the lower surface of the third press hammer 10 is provided with a punch 11 for punching; the cooling unit 6 includes a cooling spray pipe 12 and a cooling conveyor belt 13 from top to bottom.

[0061] The heating unit can be located directly above the piercing unit, forming unit, and punching unit, or it can be located diagonally above each unit, meaning that the area enclosed by the heating cavity is larger than the area enclosed by the aforementioned units.

[0062] Optionally, the heating unit 1 includes four heating chambers and an insulation sleeve wrapped around the outside of the heating chambers. The heating unit 1 is a hollow ring that forms a square. The lower part of the hollow part is set as the interior of the polishing unit 2, which not only extends the heating space and ensures the heating effect, but also makes full use of the space below the hollow part through the polishing unit 2.

[0063] The first heating chamber 15, the second heating chamber 16, the third heating chamber 17, and the fourth heating chamber 18 are arranged in a counterclockwise direction and connected end to end to form an internally continuous heating channel; heating temperature control devices are respectively provided on the outside of the first heating chamber 15, the second heating chamber 16, the third heating chamber 17, and the fourth heating chamber 18, so that the temperature of the four heating chambers gradually increases.

[0064] The first heating chamber 15 has a raw material inlet at the beginning and a heating material outlet at the end of the fourth heating chamber 18.

[0065] Optionally, the integrated device further includes a feeder 19, which includes a support and an inclined feeding conveyor belt. The beginning of the feeding conveyor belt is on the ground, and the end is connected to the beginning of the first heating chamber 15. The support is used to support the feeding conveyor belt. The feeding conveyor belt is a regular conveyor belt. The raw material pile on the ground rises along the feeding conveyor belt to the height of the first heating chamber 15 and is fed into the first heating chamber 15.

[0066] Optionally, a first transition portion 20 is provided at the connection between the end of the first heating chamber 15 and the beginning of the second heating chamber 16, a second transition portion 21 is provided at the connection between the end of the second heating chamber 16 and the beginning of the third heating chamber 17, and a third transition portion 22 is provided at the connection between the end of the third heating chamber 17 and the beginning of the fourth heating chamber 18. Each of the above transition portions is used to adjust the moving direction of the raw material block transmitted from the low-temperature side heating chamber, so that it can enter the connected high-temperature side heating chamber.

[0067] Optionally, the first adapter 20 includes a first gripper 23, a first slide bar, and a first guide rail 25. The first guide rail 25 is located between the end of the first heating cavity 15 and the beginning of the second heating cavity 16. The first guide rail 25 is an arc shape protruding outward from the heating cavity and is horizontal. The end of the first guide rail 25 near the first heating cavity 15 is provided with a straight section guide rail 26 parallel to the second heating cavity 16. The straight section guide rail 26 points to the beginning of the second heating cavity 16.

[0068] The first gripper 23 is slidably connected to the first guide rail 25 via the first slide rod and slides along the first guide rail 25. The two handles 27 of the first gripper 23 face the outside of the heating unit 1, and the two jaws 28 point to the inside of the heating unit 1. The jaws 28 are used to clamp the raw material block that moves between the first heating chamber 15 and the second heating chamber 16, and then drive the raw material block to rotate 90° clockwise to a direction parallel to the second heating chamber 16. The first gripper 23 and the first slide rod move along the straight section of the guide rail toward the second heating chamber 16, thereby pushing the raw material block into the second heating chamber 16.

[0069] In use, the raw material block is fed into the first heating chamber 15 by the feeding conveyor belt. At this time, the raw material block is parallel to the first heating chamber 15. The raw material block in front is pushed forward by the raw material block behind, moving along each heating chamber (counterclockwise). After being heated by each heating chamber with gradually increasing temperature, this is a stepped heating method, which can heat the raw material block more thoroughly and reduce the adverse thermal effects of direct high-temperature heating on the raw material block. When a raw material block moves to the end of the first heating chamber 15, it is pushed forward by the raw material block behind and enters between the two jaws of the first gripper 23, where it is clamped. The first sliding rod drives the first gripper 23 to move along the first guide rail 25 towards the first heating chamber 15, causing the clamped raw material block to rotate 90° clockwise, that is, rotated to be parallel to the second heating chamber 16. The first sliding rod then moves along the straight section of the guide rail towards the second heating chamber 16, thus pushing the clamped raw material block into the beginning of the second heating chamber 16.

[0070] Optionally, the structure of the second adapter 21 is the same as that of the first adapter 20. That is, the second adapter 21 includes a second gripper, a second slide bar and a second guide rail. The second guide rail is located between the end of the second heating cavity 16 and the beginning of the third heating cavity 17. The second guide rail is an arc shape protruding outward from the heating cavity and is horizontal. The end of the second guide rail near the second heating cavity 16 is provided with a straight section of the guide rail parallel to the third heating cavity 17. The straight section of the guide rail points to the beginning of the third heating cavity 17.

[0071] The second transfer unit 21 operates in the same way as the first transfer unit 20, transferring the raw material block that has been moved to the end of the second heating chamber 16 to the beginning of the third heating chamber 17 and pushing it into the third heating chamber 17.

[0072] Optionally, the structure of the third adapter 22 is the same as that of the first adapter 20, that is, the third adapter 22 includes a third gripper, a third slide bar and a third guide rail. The third guide rail is located between the end of the third heating cavity 17 and the beginning of the fourth heating cavity 18. The third guide rail is an arc shape protruding outward from the heating cavity and is horizontal. The end of the third guide rail near the third heating cavity 17 is provided with a straight section of the guide rail parallel to the fourth heating cavity 18. The straight section of the guide rail points to the beginning of the fourth heating cavity 18.

[0073] The inner side of the jaws of the third gripper is an outwardly convex arc surface to accommodate the circular outer side of the raw material block that is being gripped and heated to a higher temperature; a turntable 29 is provided below the third gripper, which can rotate synchronously with the third gripper.

[0074] The third transfer section 22 operates in the same way as the first transfer section 20, transferring the raw material block that has been moved to the end of the third heating chamber 17 to the beginning of the fourth heating chamber 18 and pushing it into the fourth heating chamber 18. At the same time, since the raw material block softens after being heated by the third heating chamber 17, it is easily deformed under external force, which is not conducive to the manufacture of anchors. The inner side of the jaws of the third gripper is adapted to the shape of the raw material block, which helps to maintain its shape. When the third gripper holds the raw material block, the raw material block is on the turntable 29. The turntable 29, which loads the raw material block, rotates with the third gripper, reducing the friction between the raw material block and the bottom surface of the heating chamber, thus reducing scratches on the outer surface.

[0075] Optionally, the insulation sleeve is fitted around the outside of the heating chamber for heat insulation, while avoiding affecting the various units below the heating unit 1.

[0076] Optionally, the end of the fourth heating chamber 18 is provided with a vertical hot material conveyor belt 30 for transporting the raw material block heated by the heating unit 1 to the block unit 3; the hot material conveyor belt 30 is a vertically placed ordinary conveyor belt.

[0077] Several hot material receiving parts 31 are evenly arranged on the hot material conveyor belt 30. The hot material receiving parts 31 are connected to the hot material conveyor belt 30 through the rotating seat 32. The hot material receiving part 31 includes a first plate 33 and a second plate 34 that are perpendicular to each other, and the bottoms of the two are fixedly connected to each other, which is L-shaped. The first plate 33 is close to the side of the fourth heating chamber 18, and the second plate 34 is close to the side of the block unit 3. The hot material receiving part 31 can rotate under the drive of the rotating seat 32, which facilitates the transport of the material output of the heating unit 1 to the block unit 3.

[0078] Further optionally, the rotating seat 32 is equipped with a motor inside, and the motor shaft passes through the outer shell of the rotating seat 32 and connects to the connection between the first plate 33 and the second plate 34, for controlling the horizontal rotation of the hot material receiving part 31.

[0079] The side of the first plate 33 facing the second plate 34 is the inner side. The inner side of the first plate 33 is provided with a push plate 35, which is parallel to the first plate 33. The push plate 35 can extend and retract along the second plate 34 to push the raw material block on the hot material receiving part 31 to move towards the block unit 3.

[0080] The telescopic mechanism of the push plate 35 adopts a conventional form, for example, a telescopic device is provided on the outer side of the first plate 33 to push the push plate 35 to telescopically move.

[0081] After being heated by the fourth heating chamber 18, the raw material block is in a red-hot state, and the curved surface of the cylinder is placed horizontally, i.e., the raw material block is lying flat. The hot material receiving part 31 moves from top to bottom to the end of the fourth heating chamber 18 with the hot material conveyor belt 30. The opening of the hot material receiving part 31 faces the fourth heating chamber 18, i.e., the right-angled inner side of the L-shaped hot material receiving part 31 faces the fourth heating chamber 18, and is used to receive the raw material block. The outermost raw material block of the fourth heating chamber 18 is pushed out by the inner raw material block and moved to the inner side of the first plate 33 (i.e., the push plate 35). At this time, the first plate 33 is horizontal and the second plate 34 is vertical. During the downward movement, the hot material receiving part 31 is driven to rotate 90° clockwise by the motor in the rotating seat 32 (i.e., the first plate 33 is vertical), so that the curved surface of the raw material block it carries is vertical, i.e., the raw material block is upright. When the hot material receiving part 31 descends to the bottom of the hot material conveyor belt 30, the hot material conveyor belt 30 can be paused, the second plate 34 connects to the horizontal conveyor belt 36 of the pier section unit 3, and the push plate 35 pushes out horizontally, pushing the raw material pier to the horizontal conveyor belt 36. At this time, the raw material pier still remains upright.

[0082] Optionally, the pier segment unit 3 includes a first press hammer 8, a first robotic arm, and a pier segment platform 14. The first robotic arm holds the red-hot raw material pier delivered by the horizontal conveyor belt 36 and then moves it to the pier segment platform. The first press hammer 8 is located above the pier segment platform. The head of the first press hammer 8 falls and strikes the vertical red-hot raw material pier. The first robotic arm then sends the forged raw material pier back to the horizontal conveyor belt 36, and then holds the next red-hot raw material pier, waiting for forging and striking, and so on.

[0083] The functions of the upsetting unit 3 are: (1) to remove the oxide scale generated on the surface of the raw material upsetting metal during the heating process; (2) when the raw material upsetting is formed, the shearing will form cross-sectional defects. By flattening the metal end face, the above-mentioned cross-sectional defects can be removed and the parallelism of the upper and lower end faces of the raw material upsetting can be ensured, so as to prepare the billet for the next step of die forging; (3) during the upsetting deformation, the basic forging deformation amount is ensured. At the same time, under the axial pressure of the raw material upsetting, the internal structure of the metal is flattened and stretched in the horizontal direction, so that the original defects such as pores and shrinkage in the metal are improved in the direction of crushing, refining and pressing.

[0084] Optionally, the molding unit 4 includes a second press hammer 9, an openable mold 37, and a second robotic arm. The second robotic arm grips the raw material block that has passed through the block section and is sent by the horizontal conveyor belt 36, and vertically places it into the open mold 37. The raw material block is inside the mold 37, so that the mold 37 cannot be completely closed when the upper and lower parts are closed. The hammer head of the second press 9 falls and strikes the mold 37 until the mold 37 is completely closed. The second robotic arm then opens the mold 37, takes out the molded raw material block and sends it back to the horizontal conveyor belt 36, and then grips the next raw material block to be molded, waiting for the molding to strike, and so on.

[0085] The impact of forming unit 4 causes the raw material abutment to collapse vertically and fill the cavity of mold 37 radially until mold 37 closes. During this process, the raw material abutment continues to be compressed and deformed axially, accompanied by horizontal (radial) extension. When the radial extension reaches the inner wall of the cavity of mold 37, the raw material abutment is constrained by the cavity of mold 37 and fills the cavity. When the raw material abutment fills the cavity of mold 37, it continues to be squeezed by the upper and lower parts of mold 37 until mold 37 is completely closed. In this stage, the metal is subjected to omnidirectional compression, which is the optimal stress state for improving the internal structure of the metal, refining grains, and eliminating defects; it plays a key role in improving the overall mechanical properties of the metal.

[0086] Optionally, the punching unit 5 includes a third press hammer 10, a third robot arm, and a punching lower die cavity 38. The lower surface of the third press hammer 10 is provided with a plurality of embedded combination punches 11, the bottom end of which is columnar and used for punching.

[0087] The third robotic arm grips the formed raw material block delivered by the horizontal conveyor belt 36 and vertically places it into the punching die cavity 38. The hammer head 10 of the third press falls, and the punch 11 presses into the raw material block to form a hole. The third robotic arm then takes out the raw material block and sends it back to the horizontal conveyor belt 36, and then grips the next raw material block to be punched, waiting for the punching to strike, and so on.

[0088] The punch 11 of the punching unit 5 has a cylindrical bottom and a conical top. The cylindrical part is used for pressing holes, and as the punch 11 presses down, the conical part continues to press holes, expanding the conical hole. While the metal in the part pressed into the punch 11 is subjected to axial pressure, it also generates radial (horizontal) force, causing horizontal extrusion on the raw material. As the punch 11 continues to press in, this extrusion force increases significantly when the conical part is pressed in, generating sufficiently large radial extrusion deformation on the interior of the raw material, thereby further optimizing the internal structure of the metal in the horizontal direction and improving internal defects.

[0089] Optionally, the piercing unit 3, forming unit 4, punching unit 5 and cooling unit 6 are arranged in a counterclockwise direction on the outer side of the polishing unit 2, such that the piercing unit 3 is below the first heating chamber 15, the forming unit 4 is below the second heating chamber 16, the punching unit 5 is below the third heating chamber 17, and the cooling unit 6 is below the fourth heating chamber 18.

[0090] The horizontal conveyor belt 36 is horizontally arranged and surrounds the outer side of the polishing unit 2 in a counterclockwise direction, and is located below the pier unit 3, the forming unit 4 and the punching unit 5, for transferring raw material piers between the above three units.

[0091] Optionally, the cooling spray pipe 12 of the cooling unit 6 is evenly provided with several nozzles for spraying cooling water downwards to cool the raw material block after punching; the cooling conveyor belt 13 includes several inclined sub-belts 40 from top to bottom, with the inclination directions of two adjacent sub-belts 40 being opposite and connected end to end to form several zigzag patterns, and the horizontal conveyor belt 36 connecting to the bottom end of the lowest sub-belt 40. Each sub-belt 40 can transport the raw material block it carries upwards, so that the raw material block after punching is cooled by cooling water as it moves and rises along each sub-belt 40.

[0092] The raw material pier is always upright when it is on the horizontal conveyor belt 36. When the raw material pier enters the inclined sub-belt 40, it is in a side-lying state, that is, the axial direction is parallel to the sub-belt 40.

[0093] Optionally, each strip 40 has a horizontal pushing section 41 at its bottom end, and the moving direction of the pushing section 41 is the same as the moving direction of its respective strip 40. When the raw material block moves to the top of the lower strip 40, it is pushed to the pushing section 41 of the upper strip 40, and changes its moving direction on the pushing section 41, with the original front end becoming the rear end and the original rear end becoming the front end, and continues to move along the upper strip 40.

[0094] The cooling unit 6 of the present invention is located below the fourth heating chamber 18, which has the highest temperature. It has the heat insulation effect of the heat insulation sleeve, and with the cooling of the cooling spray water, the cooling conveyor belt 13 is less affected by the heating unit 1.

[0095] Optionally, a drying hopper 42 is also hung on the outer surface of the polishing unit 2 where the cooling unit 6 is located, for collecting the cooled workpieces, drying them, and then pouring them into the polishing unit 2.

[0096] Drying fans are installed above and below the drying hopper 42 to blow air into the drying hopper 42.

[0097] Further optionally, the drying hopper 42 is a cube, including an upper frame 43 and a lower frame 24. The top and bottom surfaces of the upper frame 43 are open, and it only has mesh sides around the perimeter. The top surface of the lower frame 24 is open, and it has a mesh bottom surface and mesh sides around the perimeter. Hooks 39 are provided on the four top edges of the lower frame 24 respectively.

[0098] The lower slide frame 24 is slidably connected to the outside of the upper frame 43. By adjusting the hooks 39 to hook onto the upper frame 43 at different positions, the total length of the drying hopper 42 is adjusted, requiring all the hooks 39 on the four top edges of the lower slide frame 24 to hook onto the upper frame 43 at the same height, so that the lower slide frame 24 remains horizontal.

[0099] After cooling, the workpieces move from the top conveyor belt 40 and fall into the adjacent drying hopper 42. The upper and lower drying fans continuously supply air to the drying hopper 42 for drying. When there are few workpieces in the drying hopper 42, the hook 39 is attached to the top edge of the upper frame 43, and the drying hopper 42 is at its shortest height. As the number of workpieces increases, the hook 39 moves downward, causing the lower sliding frame 24 to move downward, increasing the height of the drying hopper 42. This continues until the hook 39 hooks onto the bottom of the upper frame 43, reaching the maximum height of the drying hopper 42 and maximizing the number of workpieces it can hold. The drying hopper 42 is then lifted manually or mechanically, and the workpieces are poured into the polishing unit 2 to remove the oxide scale from the workpiece surface.

[0100] Optionally, the polishing unit 2 is a drum-type shot blasting machine; the first press hammer 8, the second press hammer 9, and the third press hammer 10 are all JW31-500 presses with a specification of 5000KN.

[0101] Optionally, the discharge port of the polishing unit 2 is connected to a lathe, and the polished workpiece is sent to the lathe, where a pneumatic fixture and a lathe are used to process the workpiece to the required size.

[0102] Optionally, a press can also be installed on the outside of the integrated device. The press is equipped with a pressure head corresponding to the number of holes in the workpiece. The holes in the workpiece are shaped at room temperature. Specifically, the pressure head is used to press and deform the holes in the workpiece, thereby strengthening and improving the surface hardness, wear resistance and fatigue toughness.

[0103] The press performs tapered reinforcement on the holes of the workpiece to ensure the position accuracy of each tapered hole, guarantee that the hole shape meets the design requirements, and greatly change the shape and surface roughness of the tapered hole. Tapered reinforcement eliminates and improves defects and micro-defects on the surface and near the surface of the tapered hole, resulting in a sufficient work hardening effect on the metal surface, which improves the surface hardness, wear resistance, fatigue toughness and yield strength.

[0104] The calibrated workpiece is a qualified anchor product.

Claims

1. An integrated device for making high strength anchors, characterized by, The application relates to a heating and polishing device, which comprises a heating unit and a polishing unit, wherein the heating unit is above the polishing unit, the outer side of the polishing unit is provided with a segment unit, a forming unit, a punching unit and a cooling unit in a clockwise or counterclockwise direction, the heating unit comprises four heating cavities connected in a square shape, the temperature of the heating cavities gradually increases in a clockwise or counterclockwise direction, the raw material segment is input from the start end of the heating cavity with the lowest temperature, sequentially passes through the heating cavities and is heated, and is output from the heating cavity with the highest temperature, and the heating is completed. The segment unit comprises a first press hammer head, the forming unit comprises a second press hammer head and an openable and closable mold, the punching unit comprises a third press hammer head, the lower surface of the third press hammer head is provided with a punch for punching, and the cooling unit comprises a cooling spray pipe and a cooling conveying belt from top to bottom. The heating unit comprises four heating cavities and a heat preservation sleeve wrapped outside the heating cavities, and the heating unit is a hollow ring-shaped square. The first heating cavity, the second heating cavity, the third heating cavity and the fourth heating cavity are sequentially arranged in a counterclockwise direction and are connected at the start end and the end, so as to form an internal coherent heating channel. The end of the first heating cavity and the start end of the second heating cavity are provided with a first adapter, the first adapter comprises a first grab pincer, a first sliding rod and a first guide rail, the first guide rail is arranged between the end of the first heating cavity and the start end of the second heating cavity, the first guide rail is a horizontal circular arc protruding outward of the heating cavity, the end of the first guide rail close to the first heating cavity is provided with a straight section guide rail parallel to the second heating cavity, and the straight section guide rail points to the start end of the second heating cavity. The first grab pincer is slidably connected to the first guide rail through the first sliding rod and slides along the first guide rail, the two pincer handles of the first grab pincer face the outside of the heating unit, the two pincer heads point to the inside of the heating unit, the pincer heads are used for clamping the raw material segment moving between the first heating cavity and the second heating cavity and driving the raw material segment to rotate 90 degrees in a clockwise direction, the first grab pincer and the first sliding rod move along the straight section guide rail to the second heating cavity, so that the raw material segment is pushed into the second heating cavity. The outer side of the first heating cavity, the second heating cavity, the third heating cavity and the fourth heating cavity is respectively provided with a heating temperature control device, so that the temperature of the four heating cavities gradually increases.

2. The integrated device for making high-strength anchors according to claim 1, characterized in that, The start end of the first heating cavity is provided with a raw material segment inlet, and the end of the fourth heating cavity is provided with a heated material outlet. The end of the second heating cavity and the start end of the third heating cavity are provided with a second adapter, and the end of the third heating cavity and the start end of the fourth heating cavity are provided with a third adapter, which is used for adjusting the moving direction of the raw material segment delivered from the low-temperature side heating cavity, so that the raw material segment can enter the connected high-temperature side heating cavity.

3. The integrated device for making high-strength anchors of claim 2, wherein, The end of the fourth heating cavity is provided with a vertical heated material transmission belt, which is used for conveying the raw material segment heated by the heating unit to the segment unit.

4. The integrated device for making high-strength anchors of claim 3, wherein, The heated material transmission belt is uniformly provided with a plurality of heated material supporting parts connected to the heated material transmission belt through rotating seats, the heated material supporting parts comprise a first plate and a second plate perpendicular to each other, the heated material supporting parts can rotate under the driving of the rotating seats, the second plate is connected to the horizontal conveying belt of the segment unit, and the heated material supporting parts are convenient for conveying the material discharged from the heating unit to the segment unit. ​ The horizontal conveying belt is horizontally arranged and surrounds the outer side of the throwing and grinding unit in a counterclockwise direction and is below the pier segment unit, the forming unit and the punching unit, and is used for conveying the raw material pier between the three units.

5. The integrated device for making high-strength anchors of claim 4, wherein, The pier segment unit comprises a first press hammer head, a first mechanical arm and a pier segment platform, the first mechanical arm clamps the red-hot raw material pier sent by the horizontal conveying belt and then moves the raw material pier to the pier segment platform, the pier head of the first press hammer head falls and strikes the red-hot raw material pier, and the pier segment platform is used for supporting the red-hot raw material pier. The forming unit comprises a second press hammer head, an openable and closable mold and a second mechanical arm, the second mechanical arm clamps the raw material pier sent by the horizontal conveying belt and then vertically places the raw material pier into the opened mold, the pier head of the second press hammer head falls and strikes the mold until the mold is completely closed. The punching unit comprises a third press hammer head, a third mechanical arm and a punching lower mold bore, the lower surface of the third press hammer head is provided with a plurality of inlaid combined punches for punching.

6. The integrated device for making high-strength anchors of claim 5, wherein, The cooling spraying pipes of the cooling unit are uniformly provided with a plurality of spray heads for cooling the raw material pier after punching. The cooling conveying belt comprises a plurality of inclined sub-belts from top to bottom, the inclination directions of two adjacent sub-belts are opposite, and the adjacent sub-belts are connected end to end to form a plurality of zigzags.

7. The integrated device for making high-strength anchors of claim 6, wherein, The outer side of the throwing and grinding unit where the cooling unit is located is further provided with a drying hopper for collecting the workpiece after cooling and drying and then pouring the workpiece into the throwing and grinding unit. The upper and lower parts of the drying hopper are respectively provided with drying fans for blowing air into the drying hopper.

8. A method of making a high strength anchorage, characterized by, The method is implemented by using the integrated device of claim 7 and comprises the following steps: (1) processing the steel raw material into a cylindrical shape to become a raw material pier, heating the raw material pier at high temperature to obtain red-hot material; (2) hammering the red-hot material under the force of a press to obtain a pier segment material; (3) placing the pier segment material into a forming mold bore, pressing the upper and lower molds of the mold bore under the force of a press, vertically collapsing and radially filling the pier segment material into the inner cavity of the mold bore until the mold bore is closed to obtain a formed material; (4) one-time punching of the formed material under the force of a press provided with punches to form a plurality of expanded taper holes to obtain punched material; (5) throwing the punched material to remove the oxide skin on the surface of the punched material, and then using a lathe to process the punched material according to the required size of the product to obtain a semi-finished product; (6) using a press with a taper head to calibrate the through hole of the semi-finished product at room temperature to obtain an anchor product.

9. The method of fabricating a high-strength anchor of claim 8, wherein, The heating temperature of step (1) is 1050-1150℃; the pressure of the press in steps (2), (3) and (4) is 5000-6000KN; In step (4), the bottom end of the punch is cylindrical, and the top end is a taper shape expanding outward, and after the punch is pressed into the blank, an expanded taper hole with one large end and one small end is formed; In step (6), the pressure of the press is 5000-6000KN, the shape of the taper head is the same as that of the expanded taper hole, the press is pressed to make the taper head press into the expanded taper hole to strengthen the deformation, and the deformation amount of the expanded taper hole in the vertical direction is 0.4-0.5mm.

Images