Hydraulic support structure piece splicing method using nano-coated steel plate

Abstract

The application discloses a kind of hydraulic support structural member stitch welding methods of nano coating steel plate, it is related to welding technical field, first adopt plasma or laser cutting machine according to drawing requirement to steel plate is cut down material as different types of parts, after part blanking is finished, it is transferred to flame cutting machine station, mark the weld line of subsequent need welding, using the flame cutting machine without adding high-pressure oxygen to the nano coating of steel plate surface along the marked weld line is baked, to mark part's coating combustion.The application, by using numerical control flame cutting machine to the non-edge weld position on the main rib plate is baked, accurately positioned the need to polish position, while burning loss the coating of need to polish position, improve the polishing efficiency of nano coating on the main rib plate, reduce the labor intensity of worker.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and more specifically to a method for welding hydraulic support structural components using nano-coated steel plates. Background Technology

[0002] Hydraulic supports, as a primary support device in fully mechanized coal mining equipment, are customized products characterized by their large size and weight, small batch sizes, diverse types, harsh service conditions, and numerous welded structures. The top beam, shield beam, and base are the three main structural components of a hydraulic support, all of which are box-type welded structures, primarily composed of main stiffener components, top plates, stiffener plates, ear plates, and cover plates. The main weld types are fillet welds and single V-groove welds, requiring multi-layer, multi-pass welding. The structural components of hydraulic supports are mainly welded from low-alloy high-strength steel plates. To improve the corrosion resistance of hydraulic support structural components underground and extend their service life, some products require high-strength steel plates with a nano-anti-rust coating. Nano-coated steel plates are steel plates with nano-sized organic coatings sprayed on both sides before leaving the factory.

[0003] In the traditional production process of hydraulic support structural components, the parts are first cut into blanks, and the nano-coating at the weld seams is manually ground using a grinding wheel. In the assembly process, four main rib assemblies are placed on the top plate using a marking method, and the corresponding parts of the main ribs or rib plates are hammered with a sledgehammer to adjust the assembly tolerances to meet the ±1mm accuracy requirement. In the structural component welding process, the components are placed on a robotic welding platform, and appropriate welding process parameters are used to sequentially perform root pass, fill pass, and cap pass welding. All welding is done robotically, and the next weld is started after one weld is completed. In the post-weld correction process, manual welding torches are used to heat the areas requiring correction, causing deformation in areas with large deviations until the error is adjusted to within the range required by the drawings. There are many welds between the main ribs and the stiffening plates and the top plate, and the coating is relatively hard, resulting in a large amount of grinding work that is difficult to clean completely. At the same time, the grinding areas are not intuitive, and manual grinding is prone to missing the areas with welds on the main ribs. During the assembly process, the surface of the main ribs, stiffening plates and other parts is struck with a sledgehammer, which can cause damage and peeling of the surface nano-coating, affecting the corrosion resistance of the hydraulic support. In the root welding process, the organic matter in the residual nano-coating on the steel plate decomposes when heated, producing gas, which can easily cause porosity in the weld, increasing welding defects. At the same time, because the robot continuously performs root, fill and cover welding, the porosity is not easy to detect. Moreover, the porosity is at the root of the weld, which needs to be removed layer by layer by carbon arc gouging from top to bottom, making post-weld repair difficult. After welding, the deformed parts of the structural components that exceed the tolerance need to be flame corrected. The flame directly heats the surface of the steel plate coating, causing the coating to burn off.

[0004] Therefore, it is necessary to propose a welding method for hydraulic support structural components using nano-coated steel plates to solve the above problems. Summary of the Invention

[0005] (I) Technical Solution

[0006] To achieve the above objectives, the present invention specifically adopts the following technical solution: A method for welding hydraulic support structural components using nano-coated steel plates includes the following steps: S1: Parts cutting. First, use a plasma or laser cutting machine to cut the steel plate into different types of parts according to the drawing requirements. S2: Baking the nano-coating. After the parts are cut, they are transferred to the flame cutting machine station. The weld seam positions to be welded are marked. The nano-coating on the steel plate surface is baked along the marked weld seam positions using a flame cutting machine without adding high-pressure oxygen, which causes the coating at the marked area to burn. S3: Polishing the nano-coating. The parts are transferred to the polishing station and a grinding wheel is used to clean the residual coating, oxides and impurities on the baked parts and 20mm on both sides. S4: Assembly. The top plate is placed on the assembly station. The position lines of each part are marked on the top plate and the main ribs. The main ribs and internal rib plate parts are assembled on the top plate. For the part where the assembly accuracy error between the main ribs exceeds 1mm, a 0.5mm thick square copper sheet with a side length of 200mm is placed at the part where the accuracy of the main rib exceeds the tolerance. A magnet is placed on the upper edge of the copper sheet. The copper sheet is fixed by the magnetic force between the magnet and the part. The part where the copper sheet is placed is manually tapped with a sledgehammer to make fine adjustments to the assembly dimensions until the tolerance accuracy requirement of ±1mm is met. After the assembly dimensions are adjusted, the assembled workpiece is tack welded. S5: Welding. The assembled structural components are placed on the welding platform. The overall root weld of the structural components is carried out by manual welding. After welding, the defects of the root weld are inspected by visual inspection. If there are defects, they are directly repaired. After the manual root welding process is completed, the welding robot is used to perform the root, fill and cover welding in sequence. S6: Post-weld correction, flame correction of deformed parts after welding. Before flame correction, place a 0.5mm thick strip of copper on the part to be corrected, and place a high-temperature magnet on the upper edge of the copper strip. The copper strip is fixed by the magnetic force between the magnet and the part. The copper strip is then heated directly by a flame gun to correct the deformed parts after welding. S7: Touch-up paint, spraying nano paint with the same composition as the nano coating on the steel plate onto the exposed substrate surface near the weld seam on the structural component due to grinding.

[0007] Furthermore, the baking process parameters in step S2 are as follows: the distance between the cutting nozzle and the steel plate surface is 10-12mm, and the travel speed is 600-800mm / min.

[0008] Furthermore, in step S4, the tack welding uses ER50-6φ1.2mm welding wire, welding current of 260-280A, voltage of 30-32V, welding speed of 350-400mm / min, and the length of each tack weld is 300-500mm and the height is 3-4mm.

[0009] Furthermore, in step S5, manual welding uses a mixed gas shielded welding of Ar + 20% CO2, with a solid welding wire of φ1.4mm diameter. The manual welding parameters are: welding current 300-340A, welding voltage 26-29V, welding speed 35-45cm / min, wire extension 15-25mm, shielding gas flow rate 20-25L / min, and the welding torch is pointed as evenly as possible to bisect the bevel. The robot welding parameters are: welding current 440-480A, voltage 30-33V, wire feed speed 8-10m / min, welding speed 40-50cm / min, transverse sinusoidal oscillation of the welding wire end 1-4mm, welding wire extension 20-25mm, and shielding gas flow rate 20-25L / min.

[0010] (ii) Beneficial effects

[0011] The beneficial effects of this invention are as follows: 1. This invention uses a CNC flame cutting machine to bake the non-edge weld areas on the main stiffening plate, which accurately locates the areas to be ground and burns away the coating on the areas to be ground, thereby improving the grinding efficiency of the nano-coating on the main stiffening plate and reducing the labor intensity of workers.

[0012] 2. In this invention, a method of striking with copper pads is used during the assembly process to prevent the sledgehammer from coming into direct contact with the nano-coating, thus avoiding damage to the nano-coating on the steel plate surface, reducing the difficulty of touch-up painting, and ensuring the corrosion resistance of the structural components. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the welding position in this invention.

[0014] Figure 2 This is a schematic diagram of the welding sequence of the robot according to the present invention. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Please see Figure 1 A method for welding hydraulic support structural components using nano-coated steel plates includes the following steps: S1: Parts cutting. First, use a plasma or laser cutting machine to cut the steel plate into different types of parts according to the drawing requirements. S2: Baking the nano-coating. After the parts are cut, they are transferred to the flame cutting machine station. The weld seam positions to be welded are marked. The nano-coating on the steel plate surface is baked along the marked weld seam positions using a flame cutting machine without adding high-pressure oxygen, which causes the coating at the marked area to burn. S3: Polishing the nano-coating. The parts are transferred to the polishing station and a grinding wheel is used to clean the residual coating, oxides and impurities on the baked parts and 20mm on both sides. S4: Assembly. The top plate is placed on the assembly station. The position lines of each part are marked on the top plate and main ribs. The main ribs and internal rib plate parts are assembled on the top plate. For the part where the assembly accuracy error between the main ribs exceeds 1mm, a 0.5mm thick square copper sheet with a side length of 200mm is placed at the part where the accuracy of the main rib exceeds the tolerance. A magnet is placed on the upper edge of the copper sheet. The copper sheet is fixed by the magnetic force between the magnet and the part. The part where the copper sheet is placed is manually tapped with a sledgehammer to make fine adjustments to the assembly dimensions until the tolerance accuracy requirement of ±1mm is met. After the assembly dimensions are adjusted, the assembled workpiece is tack welded. Copper sheets are placed at the parts that need to be corrected to avoid the coating burn caused by direct contact of flame with the nano coating, thus ensuring the reliability of the nano coating and ensuring the corrosion resistance of the hydraulic support in the well. S5: Welding. The assembled structural components are placed on the welding platform, and manual welding is used to perform the overall root pass welding of the structural components. After welding, the defects of the root pass weld are inspected visually. If there are defects, they are directly repaired. After the manual root pass welding process is completed, the welding robot is used to perform the root pass, fill pass and cover pass welding in sequence. First, the overall manual root pass is performed. Appropriate process parameters are selected, welding parameters are appropriately reduced, and welding speed is controlled to reduce welding defects caused by nano-coating residue. At the same time, after the overall manual root pass welding, the defects of the root pass weld are easier to find and repair, reducing the difficulty of defect repair, improving weld quality, and ensuring the fatigue life of the hydraulic support during its underground service. S6: Post-weld correction, flame correction of deformed parts after welding. Before flame correction, place a 0.5mm thick strip of copper on the part to be corrected, and place a high-temperature magnet on the upper edge of the copper strip. The copper strip is fixed by the magnetic force between the magnet and the part. The copper strip is then heated directly by a flame gun to correct the deformed parts after welding. S7: Touch-up paint, spraying nano paint with the same composition as the nano coating on the steel plate onto the exposed substrate surface near the weld seam on the structural component due to grinding.

[0017] The baking process parameters in step S2 are: the height of the cutting nozzle from the steel plate surface is 10-12mm, and the traveling speed is 600-800mm / min.

[0018] In step S4, the tack welding uses ER50-6φ1.2mm welding wire, welding current 260-280A, voltage 30-32V, welding speed 350-400mm / min, and each tack weld is 300-500mm long and 3-4mm high.

[0019] In step S5, manual welding uses a mixed gas shielded welding of Ar + 20% CO2, with a solid welding wire of φ1.4mm diameter. The manual welding parameters are: welding current 300-340A, welding voltage 26-29V, welding speed 35-45cm / min, wire extension 15-25mm, shielding gas flow rate 20-25L / min, and the welding torch should be pointed as evenly as possible to bisect the bevel. The robot welding parameters are: welding current 440-480A, voltage 30-33V, wire feed speed 8-10m / min, welding speed 40-50cm / min, transverse sinusoidal oscillation of the welding wire end 1-4mm, welding wire extension 20-25mm, and shielding gas flow rate 20-25L / min.

[0020] In summary, this invention improves the grinding efficiency of the nano-coating on the main stiffening plate, reduces the labor intensity of workers, reduces the difficulty of paint touch-up, ensures the corrosion resistance of structural components, reduces the difficulty of defect repair, improves weld quality, ensures the fatigue life of the hydraulic support during its underground service, ensures the reliability of the nano-coating, and ensures the corrosion resistance of the hydraulic support underground.

[0021] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0022] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for welding hydraulic support structural components made of nano-coated steel plates, characterized in that: Includes the following steps: S1: Parts cutting. First, use a plasma or laser cutting machine to cut the steel plate into different types of parts according to the drawing requirements. S2: Baking the nano-coating. After the parts are cut, they are transferred to the flame cutting machine station. The weld seam positions to be welded are marked. The nano-coating on the steel plate surface is baked along the marked weld seam positions using a flame cutting machine without adding high-pressure oxygen, which causes the coating at the marked area to burn. S3: Polishing the nano-coating. The parts are transferred to the polishing station and a grinding wheel is used to clean the residual coating, oxides and impurities on the baked parts and 20mm on both sides. S4: Assembly. The top plate is placed on the assembly station. The position lines of each part are marked on the top plate and the main ribs. The main ribs and internal rib plate parts are assembled on the top plate. For the part where the assembly accuracy error between the main ribs exceeds 1mm, a 0.5mm thick square copper sheet with a side length of 200mm is placed at the part where the accuracy of the main rib exceeds the tolerance. A magnet is placed on the upper edge of the copper sheet. The copper sheet is fixed by the magnetic force between the magnet and the part. The part where the copper sheet is placed is manually tapped with a sledgehammer to make fine adjustments to the assembly dimensions until the tolerance accuracy requirement of ±1mm is met. After the assembly dimensions are adjusted, the assembled workpiece is tack welded. S5: Welding. The assembled structural components are placed on the welding platform. The overall root weld of the structural components is performed by manual welding. After welding, the defects of the root weld are inspected by visual inspection. If there are porosity defects, they are directly reworked. After the manual root weld is completed, the robot performs the overall root weld first, and then the overall filling and cover welding are performed layer by layer. After each layer of weld is completed, the defects of that layer of weld are inspected by visual inspection. If there are porosity defects, they are directly reworked. S6: Post-weld correction. Flame correction is performed on the deformed parts after welding. Before flame correction, a 0.5mm thick strip of copper is placed on the part to be corrected, and a high-temperature magnet is placed on the upper edge of the copper strip. The copper strip is fixed by the magnetic force between the magnet and the part. The copper strip is heated directly by a flame gun to make the deformed parts after welding complete the correction. S7: Touch-up paint, spraying nano paint with the same composition as the nano coating on the steel plate onto the exposed substrate surface near the weld seam on the structural component due to grinding.

2. The method for welding hydraulic support structural components using nano-coated steel plates according to claim 1, characterized in that: The baking process parameters in step S2 are: the height of the cutting nozzle from the steel plate surface is 10-12mm, and the traveling speed is 600-800mm / min.

3. The method for welding hydraulic support structural components using nano-coated steel plates according to claim 1, characterized in that: In step S4, the tack welding uses ER50-6φ1.2mm welding wire, welding current 260-280A, voltage 30-32V, welding speed 350-400mm / min, and each tack weld is 300-500mm long and 3-4mm high.

4. The method for welding hydraulic support structural components using nano-coated steel plates according to claim 1, characterized in that: In step S5, manual welding uses a mixed gas shielded by Ar + 20% CO2, with a solid welding wire of φ1.4mm diameter. The manual welding parameters are: welding current 300-340A, welding voltage 26-29V, welding speed 35-45cm / min, wire extension 15-25mm, shielding gas flow rate 20-25L / min, and the welding torch should be pointed as evenly as possible to bisect the bevel. The robot welding parameters are: welding current 440-480A, voltage 30-33V, wire feed speed 8-10m / min, welding speed 40-50cm / min, transverse sinusoidal oscillation of the welding wire end 1-4mm, welding wire extension 20-25mm, and shielding gas flow rate 20-25L / min.

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