A preparation method of a roller ring of a portal-type bucket-wheel stacker-reclaimer

Abstract

This invention relates to the field of bucket wheel excavator roller manufacturing technology, and particularly to a method for manufacturing a roller ring for a gantry bucket wheel stacker-reclaimer. According to the roller's design requirements, the various components of the roller are cut; the components are assembled and welded to form a complete roller; the complete roller is disassembled into three parts; each part of the disassembled roller is tempered to eliminate residual welding stress; the disassembled roller is reassembled and machined to achieve the required roundness of the roller track; the surface of the machined roller track is quenched; the hopper is assembled to form the roller ring; and the roller ring is cleaned, sandblasted, and painted. The roller ring prepared by this invention results in a rigid and stable roller structure, lightweight and resistant to deformation. Simultaneously, the upper and lower track surfaces have high hardness and a moderate hardness layer thickness, improving the track's wear resistance. Precise disassembly and positioning for installation achieve stable roller operation, long service life, and ease of installation and transportation.

Description

Technical Field

[0001] This invention relates to the field of bucket wheel excavator roller manufacturing technology, and in particular to a method for manufacturing a gantry bucket wheel stacker-reclaimer roller. Background Technology

[0002] Gantry stacker-reclaimers, as a continuous and efficient bulk material handling and conveying machine, have been widely used in many industries such as power plants, steel mills, ports, and mines. The use of gantry stacker-reclaimers as bulk material handling machinery began abroad in the early 20th century, evolving from bucket wheel excavators. my country began developing bucket wheel stacker-reclaimers in the mid-1960s, and especially in the late 1980s, with the development of the power and steel industries, the stacker-reclaimer industry experienced rapid growth. Its high recovery rate, convenient operation, flat material pile, ease of management, and ease of automation control enable high and low-level stacking and reclaiming operations across material yards, and it can perform multiple functions such as stacking, reversing, and direct reclaiming.

[0003] During the operation of a gantry bucket wheel stacker-reclaimer, the roller ring is the most vulnerable component. If the roundness and hardness of the rollers do not meet requirements during manufacturing, they are extremely prone to deformation under continuous heavy loads. Simultaneously, insufficient roundness and hardness of the track lead to unstable roller operation, and poor wear resistance at the track-support wheel contact points, resulting in a short service life for the rollers. Furthermore, the large overall size of the rollers makes transportation extremely inconvenient. Summary of the Invention

[0004] To address at least one of the aforementioned technical problems, this invention proposes a method for preparing the roller ring of a gantry bucket wheel stacker-reclaimer. The method involves integral processing via assembly welding, welding the upper and lower rails to the roller structure base, and then precision machining to prepare the roller. The roller is then precisely disassembled and positioned for installation. Simultaneously, the welded roller undergoes residual welding stress elimination and ultrasonic induction hardening treatment. This method solves the problems of easy deformation of the roller ring during operation, easy wear of the rails, short service life of the roller ring, and inconvenience in transportation.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for preparing a rolling ring for a gantry bucket wheel stacker-reclaimer includes the following steps:

[0007] S1. According to the design requirements of the roller, cut the materials for each component of the roller;

[0008] S2, Assemble and weld the various components of the roller to form a complete roller;

[0009] S3, disassembles the complete roller into three parts;

[0010] S4. Tempering is performed on each part of the disassembled roller to eliminate residual welding stress.

[0011] S5. After the disassembled rollers are reassembled into a round shape, they are machined to make the roller tracks meet the roundness requirements.

[0012] S6, the track surface of the roller after machining is hardened;

[0013] S7, the assembly hopper forms a rolling ring;

[0014] S8 involves cleaning, sandblasting, and painting the roller ring.

[0015] Preferably, the components include an outer plate for mounting the hopper, an inner plate concentric with and located inside the outer plate, an upper ring plate and a lower ring plate surrounding the inner plate and the outer plate on both sides, and an upper track and a lower track located at the lower part of the upper ring plate and the lower ring plate and on both sides of the lower end of the inner plate.

[0016] The track is made of 45# steel plate and its chemical composition is re-inspected. The thickness and width of the 45# steel plate should allow for machining allowance. The shrinkage of welding should be considered when cutting the upper and lower circular ring plates.

[0017] Preferably, S2 includes:

[0018] S2.1, When assembling or stacking round tires on the platform, the flatness is ±1mm;

[0019] S2.2, Mark the ground, use a marking gauge to determine the inner and outer circles of the upper and lower circular plates to ensure concentricity, and at the same time ensure that the track side diameter of the upper and lower circular plates should be 6-8 mm larger than the design diameter;

[0020] S2.3, with the lower ring plate as the base, assemble the lower flange plate according to the ground sample, level it after splicing and use a compass to find the circle;

[0021] S2.4, Draw the assembly lines of the outer ring plate, inner ring plate, lower stiffener plate and upper stiffener plate on the lower ring plate;

[0022] S2.5 After the outer plate is cut, accurately mark the square holes for hopper installation on the outer plate and cut them intermittently; roll the outer plate and inner plate and measure the roundness with a template and correct it with flame until it meets the requirements of the drawing. The roundness diameter of the outer plate should be 6-8 mm larger than the design diameter when rolling; assemble the outer plate, inner plate, upper ring plate and lower stiffening plate in sequence.

[0023] S2.6, Assemble the lower and upper rails. The roundness of the upper and lower rails needs to be corrected by flame until it meets the requirements of the drawing. When the lower and upper rails are in a free state, their rolled roundness diameter should be 6-8 mm larger than the design diameter. The assembly gap should be within 0-2 mm to ensure the flatness and roundness of the rails.

[0024] S2.7, accurately divide the circle and assemble the upper stiffening plate and upper flange, ensuring that the upper stiffening plate is perpendicular to the upper flange and spot welded to fix it;

[0025] S2.8, after the upper and lower stiffening plates are double-layered and reinforced, carbon dioxide gas shielded welding is used to weld each component;

[0026] S2.9, After welding, inspect the perpendicularity and roundness of the upper and lower rails.

[0027] Preferably, the ellipticity and radial runout of the upper and lower tracks are no greater than 1.5 mm, the end face runout is no greater than 2.5 mm, and the outer circle ellipticity is no greater than 5 mm.

[0028] Preferably, S3 includes:

[0029] S3.1 Before disassembly, with the roller under double-layer tension of the upper and lower stiffening plates, check the overall dimensions of the roller and mark the assembly line and disassembly line of the connecting plate.

[0030] S3.2, When disassembling the roller, cut the roller straight along the disassembly line;

[0031] S3.3, Cut the hopper hole along the square hole line of the hopper, and after disassembly, check the perpendicularity of the upper and lower rails and the chord length of each roller;

[0032] S3.4 After the roller is disassembled into three parts, a connecting plate is assembled and welded at the disassembly port.

[0033] Preferably, S4 includes:

[0034] S4.1, flatten the three parts of the roller in the heat treatment furnace respectively;

[0035] S4.2, heat the temperature inside the heat treatment furnace to 630-650℃ and hold it for 3-4 hours, then cool it down with the furnace.

[0036] Preferably, the heating rate of the heat treatment furnace is <80°C.

[0037] Preferably, S5 includes:

[0038] S5.1, Remove the top and bottom stiffening plates on the platform and mark the alignment lines for the connecting plate group;

[0039] S5.2, Machin the plane of the connecting plate and mark the center line of the connecting plate hole, and drill the connecting plate hole with a jig;

[0040] S5.3, round the three parts of the disassembled roller on the vertical lathe;

[0041] S5.4. Align with the track line, rough machine the track, and leave a 3-5mm machining allowance in the diameter direction after rough machining; when finishing the track, loosen the chuck appropriately to reduce the clamping force and ensure that the clamping force is uniform.

[0042] S5.5, mark the center line and pin hole line of the pin hole, drill the pin hole and assemble the pin.

[0043] Preferably, S6 includes:

[0044] S6.1 After the upper and lower track rolling rings that have been machined pass the overall inspection, the surfaces of the upper and lower track are hardened.

[0045] S6.2 After the quenching process is completed, check the surface hardness, roundness and perpendicularity of the upper and lower rails to see if they meet the design standards.

[0046] Preferably, the quenching treatment adopts ultrasonic induction quenching. During the quenching treatment, the workpiece is rotated, and a U-shaped quenching heating ring is made according to the shape of the upper and lower rails. The quenching temperature is 830-860℃. After quenching, water cooling is performed to rapidly harden the surface and form a martensitic structure. The surface hardness of the upper and lower rails in contact with the support wheel after quenching treatment should reach HRC48-55, and the hardness layer depth should be 3-4mm.

[0047] Compared with the prior art, the present invention has the following beneficial effects:

[0048] This invention utilizes a modular welding process to fabricate the roller as a whole. The upper and lower rails are welded to the roller structure base and then precision-machined. The roller is then precisely disassembled, and residual welding stress is eliminated. The roller rails undergo ultrasonic induction hardening treatment, resulting in a rigid and stable roller structure that is lightweight and resistant to deformation. Simultaneously, the upper and lower rails exhibit high surface hardness and a moderate hardness layer thickness, improving wear resistance and achieving stable roller operation and a long service life. By disassembling the roller into three parts and using pins for positioning and installation on the connecting plate at the disassembly point and on the rails, the roller can be transported separately without easily deforming during transport. This also facilitates subsequent high-precision assembly and installation, resulting in a roller and rail with excellent roundness and installation accuracy, meeting the requirements for stable operation. Attached Figure Description

[0049] Figure 1 A schematic diagram of the rolling ring structure of a portal bucket wheel stacker-reclaimer;

[0050] Figure 2 for Figure 1Sectional view along axis AA;

[0051] Figure 3 This is a schematic diagram showing the distribution of the pin holes in the connecting plate, upper track, and lower track in this invention;

[0052] Figure 4 for Figure 3 Enlarged view of point A in the middle;

[0053] Figure 5 This is a schematic diagram of the process support structure in this invention;

[0054] Figure 6 This is a partial unfolded view of the rollers in this invention;

[0055] In the diagram: 1. Upper rail; 2. Upper flange; 3. Pin; 4. Upper stiffening plate; 5. Upper ring plate; 6. Upper partition plate; 7. Inner enclosure plate; 8. Outer enclosure plate; 9. Lower partition plate; 10. Lower ring plate; 11. Lower stiffening plate; 12. Lower flange; 13. Lower rail; 14. Pin hole; 15. Roller; 16. Hopper; 17. Process support structure; 171. Triangular frame; 172. Support rod; 18. Connecting plate; 19. Square hole. Detailed Implementation

[0056] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments of the present invention.

[0057] Please refer to Figure 1-6 As shown, a method for preparing a rolling ring for a gantry bucket wheel stacker-reclaimer includes the following steps:

[0058] S1. According to the design requirements of roller 15, cut the materials for each component of roller 15.

[0059] Specifically, such as Figure 2 As shown, the main components of the roller 15 include an outer plate 8 for mounting the hopper 16, an inner plate 7 concentric with and located inside the outer plate 8, an upper ring plate 5 and a lower ring plate 10 surrounding the inner plate 7 and the outer plate 8 on both sides, and an upper track 1 and a lower track 13 located below the upper ring plate 5 and the lower ring plate 10 and on both sides of the lower end of the inner plate 7.

[0060] The upper track 1 and lower track 13 are made of 45# steel plate, and their chemical composition is re-tested. The purpose of the chemical composition re-test is to determine whether the carbon content in the 45# steel plate meets the standard, so as to avoid the track made of 45# steel plate failing to meet the hardness requirements after quenching treatment.

[0061] In addition, machining allowances should be reserved for the thickness and width of the 45# steel plate. Specifically, the thickness of the 45# steel plate should be 10-15mm larger than the design thickness of the track, and the width should be 20mm larger than the design width of the track. When cutting the upper ring plate 5 and the lower ring plate 10, the shrinkage due to welding should be taken into account. Their inner and outer diameters should be 6-8mm larger than the design diameter to ensure that sufficient allowance is reserved during the welding process to compensate for shrinkage deformation and stress release after welding.

[0062] S2, the various components of the welding roller 15 are assembled to form a complete roller 15.

[0063] Specifically, S2 includes:

[0064] S2.1, When assembling or stacking round tires on the platform, the flatness is ±1mm;

[0065] S2.2, Mark the ground, use a marking gauge to determine the inner and outer circles of the upper circular plate 5 and the lower circular plate 10 to ensure concentricity, and at the same time ensure that the track side diameter of the upper circular plate 5 and the lower circular plate 10 should be 6-8 mm larger than the design diameter;

[0066] S2.3, with the lower ring plate 10 as the base, assemble the lower flange plate 12 according to the ground sample, and after splicing, level it and use a scribe to find the circle;

[0067] S2.4 Mark the assembly lines of the outer ring plate 8, inner ring plate 7, lower stiffening plate 11 and upper stiffening plate 4 on the lower ring plate 10 to facilitate the assembly and installation of the outer ring plate 8, inner ring plate 7, lower stiffening plate 11 and upper stiffening plate 4.

[0068] S2.5 After the outer plate 8 is cut, the square holes 19 for the installation of the hopper 16 are accurately marked on the outer plate 8 and cut intermittently; roll the outer plate 8 and the inner plate 7 and measure the roundness with a template and correct it with flame until it meets the requirements of the drawing. When rolling the outer plate 8, the roundness diameter should be 6-8 mm larger than the design diameter; assemble the outer plate 8, the inner plate 7, the upper ring plate 5 and the lower stiffening plate 11 in sequence.

[0069] S2.6, Assemble the lower rail 13 and the upper rail 1. The roundness of the upper rail 1 and the lower rail 13 needs to be corrected by flame until it meets the requirements of the drawing. When the lower rail 13 and the upper rail 1 are in the free state, their rolled roundness diameter should be 6-8 mm larger than the design diameter. The assembly gap should be within 0-2 mm to ensure the flatness and roundness of the rails.

[0070] Please refer to Figure 5As shown, it should be noted that, in order to facilitate the assembly of the various components of the roller 15, the free state mentioned above in this embodiment refers to the fact that a process support structure 17 is provided inside the roller 15, mainly including a triangular frame 171 connected inside the roller 15, preferably an equilateral triangular frame 171. At the same time, in order to provide stable support for the roller 15, multiple support rods 172 are provided at intervals between each side of the equilateral triangular frame 171 and the inner wall of the roller 15.

[0071] To facilitate the assembly and installation of the outer perimeter plate 8 and the inner perimeter plate 7, in this embodiment, a lower partition plate 9 near the lower annular plate 10 and an upper partition plate 6 near the upper annular plate 5 are provided between the outer perimeter plate 8 and the inner perimeter plate 7. It is understood that the upper partition plate 6 and the lower partition plate 9 serve a supporting function.

[0072] To ensure the accuracy of the roundness measurement of the upper track 1 and the lower track 13, the aforementioned process support structure 17 needs to be removed during measurement to eliminate its influence on the roundness measurement of the upper track 1 and the lower track 13, so that the upper track 1 and the lower track 13 are in a free state.

[0073] The flatness of the upper track 1 and the lower track 13 mentioned above can be measured with a level to ensure the flatness of the assembled upper track 1 and the lower track 13.

[0074] S2.7, accurately divide the circle and assemble the upper stiffening plate 4 and the upper flange 2, ensuring that the upper stiffening plate 4 is perpendicular to the upper flange 2 and spot welded to fix it.

[0075] It should be noted that pin holes 14 are provided at the corresponding positions of the upper annular plate 5 and the upper flange 2, and at the corresponding positions of the lower annular plate 10 and the lower flange 12. The upper stiffening plate 4 and the lower stiffening plate 11 are fixed by pins 3 that are adapted to the pin holes 14. By fixing the annular array centered on the upper annular plate 5 on the outer periphery of the upper annular plate 5 and the inner periphery of the lower annular plate 10 by pins 3 in the above manner, the roller 15 is secured on both sides.

[0076] S2.8, after the upper stiffening plate 4 and the lower stiffening plate 11 are double-layered and reinforced, each component is welded by carbon dioxide gas shielded welding.

[0077] Specifically, ER50-6 welding wire was used during welding. 3-4 people divide the circle into n equal parts and weld intermittently in the same direction. First, weld the vertical joints of the upper stiffening plate 4 and the lower stiffening plate 11. Weld every 2 upper stiffening plates 4 or lower stiffening plates 11 until all the vertical joints of the upper stiffening plates 4 and lower stiffening plates 11 are welded. Then, weld the horizontal joints of the upper stiffening plates 4 and lower stiffening plates 11 at the same intervals.

[0078] When welding, use a small current and maintain consistent welding specifications. Weld one layer first, then weld the second layer after flat welding and overhead welding.

[0079] First, perform an overhead weld on the fillet weld between the upper ring plate 5 and the outer ring plate 8. Then, weld the fillet weld between the lower ring plate 10 and the outer ring plate 8. Use multi-layer welding, welding intermittently one layer at a time, welding the next layer after completing the previous one. Use the above welding method to weld the circumferential seam of the upper track 1 and the lower track 13, as well as the remaining parts.

[0080] S2.9 After welding, inspect the perpendicularity and roundness of the upper rail 1 and the lower rail 13.

[0081] The ellipticity and radial runout of the upper track 1 and the lower track 13 shall not exceed 1.5 mm, the end face runout shall not exceed 2.5 mm, and the outer circle ellipticity shall not exceed 5 mm. Among them, the end face runout refers to the difference between the maximum and minimum values ​​measured by a fixed indicator in a given measurement direction during the actual rotation of the measured element around the reference axis under the condition of no axial movement.

[0082] Understandably, the good roundness of the upper track 1 and the lower track 13 enables the bucket wheel excavator's rolling ring to maintain good track stability during operation, thereby improving the service life and safety of the bucket wheel excavator.

[0083] S3, disassemble the complete roller 15 into three parts.

[0084] Specifically, S3 includes:

[0085] S3.1 Before disassembly, the roller 15 is under double-layer tension of the upper stiffening plate 4 and the lower stiffening plate 11. The overall dimensions of the roller 15 are checked, and the assembly line and disassembly line of the connecting plate 18 are marked.

[0086] S3.2 When disassembling roller 15, cut roller 15 straight along the disassembly line;

[0087] S3.3, cut the hole of hopper 16 along the square hole line of hopper 16, and after disassembly, check the perpendicularity of upper track 1 and lower track 13 and the chord length of roller 15.

[0088] S3.4 After the roller 15 is disassembled into three parts, the connecting plate 18 is assembled and welded at the disassembly port.

[0089] It should be noted that cutting the roller 15 straight along the disintegration line can maximize the straightness and precision of the disintegration openings of the three parts of the roller 15 after disintegration, reduce unnecessary deformation and damage during the cutting process, and thus ensure the structural integrity of the subsequent reassembly of the three disintegrated roller 15 parts.

[0090] S4. Tempering is performed on each part of the disassembled roller 15 to eliminate residual welding stress.

[0091] Specifically, S4 includes:

[0092] S4.1, flatten the three parts of roller 15 in the heat treatment furnace respectively;

[0093] S4.2, heat the temperature inside the heat treatment furnace to 630-650℃ and hold it at that temperature for 3-4 hours, then cool it down with the furnace. The heating rate of the heat treatment furnace should be <80℃.

[0094] It should be noted that gradually heating to the set temperature, maintaining the temperature, and cooling at an appropriate temperature can effectively eliminate residual stress that may be generated in the roller 15 after welding. This can effectively prevent the roller 15 from deforming or cracking during use, thereby improving the service life and safety of the roller 15.

[0095] In addition, the track hardening treatment can improve the hardness of the track of roller 15, so as to ensure that the track of roller 15 has good wear resistance and the overall roller has good resistance to deformation.

[0096] S5, after the disassembled roller 15 is reassembled into a round shape, it is machined to make the roller 15 meet the roundness requirements;

[0097] Specifically, S5 includes:

[0098] S5.1, Remove the upper stiffening plate 4 and the lower stiffening plate 11 on the platform, and draw 18 sets of alignment lines for the connecting plate;

[0099] S5.2, Machin the plane of the connecting plate 18 and mark the center line of the connecting plate hole, and drill the connecting plate hole with a jig;

[0100] S5.3, the three disassembled parts of roller 15 are rounded on a vertical lathe;

[0101] S5.4. Align with the track line, rough machine the track, and leave a 3-5mm machining allowance in the diameter direction after rough machining; when finishing the track, loosen the chuck appropriately to reduce the clamping force and ensure that the clamping force is uniform.

[0102] S5.5, mark the center line and pin hole line of the pin hole, drill pin hole 14 and assemble pin 3.

[0103] It should be noted that, as Figure 2 , Figure 3 and Figure 4 As shown, by marking the assembly lines of the connecting plate 18 and drilling holes in the connecting plate using the jig, the precision and accuracy of the installation of the connecting plate 18 and the opening of the connecting plate holes are ensured, the accuracy of the positioning of the connecting plate holes is ensured, and thus the assembly precision of the three parts of the roller 15 is ensured.

[0104] It should be noted that, according to the markings on the pin hole 14, pin holes 14 are drilled on the connecting plate 18, the upper rail 1, and the lower rail 13, and the pin 3 is spot-welded to the pin hole 14 so that the roller 15 can be accurately positioned during assembly, ensuring that the upper rail 1 and the lower rail 13 have high installation accuracy after installation.

[0105] S6, the track surface of the roller after machining is hardened;

[0106] Specifically, S6 includes:

[0107] S6.1 After the upper rail 1 and lower rail 13 rolling rings that have been machined pass the overall inspection, the surfaces of the upper rail 1 and lower rail 13 are quenched.

[0108] S6.2 After the quenching process is completed, check the surface hardness, roundness and perpendicularity of the upper track 1 and the lower track 13 to see if they meet the design standards.

[0109] The quenching process adopts ultrasonic induction quenching. During the quenching process, the workpiece is rotated, and a U-shaped quenching heating ring is made according to the shape of the upper rail 1 and the lower rail 13. The quenching temperature is 830-860℃. After quenching, water cooling is performed to rapidly harden the surface and form a martensitic structure. The surface hardness of the upper rail 1 and the lower rail 13 in contact with the support wheel after quenching should reach HRC48~55, and the hardness layer depth is 3-4mm.

[0110] It should be noted that if the surface hardness of the track is insufficient, the wear resistance of the upper track 1 and the lower track 13 will not meet the requirements. If the hardness layer is too thin, the durability of the upper track 1 and the lower track 13 will be poor. If the hardness layer is too thick, the hardness layer of the upper track 1 and the lower track 13 will easily fall off under the rolling pressure during operation. Therefore, after high-frequency quenching and medium-frequency quenching tests, this application finally adopted ultrasonic induction quenching, which achieved a suitable hardness and hardness layer on the track surface, thereby improving the stability and service life of the roller 15.

[0111] Please refer to Figure 6 As shown in Figure S7, the assembly hopper 16 forms a rolling ring.

[0112] It should be noted that during the installation of the hoppers 16, it is necessary to ensure that the positions of each hopper 16 correspond uniformly with the pre-drilled square holes 19. To achieve this, in this embodiment, holes are also drilled in the jig plate to ensure the relative consistency of the positions of the mounting holes of the hoppers 16 and the square holes 19, thereby ensuring the consistency of the installation positions of the hoppers 16.

[0113] S8 involves cleaning, sandblasting, and painting the roller ring.

[0114] It should be noted that, for ease of transportation, after the trial installation of hopper 16 and roller 15, hopper 16 and roller 15 should be transported separately. At the same time, to prevent deformation of roller 15 during transportation after disassembly, process bracing should be installed at the disassembly point.

[0115] This invention utilizes a modular welding process to fabricate the roller 15. The upper rail 1 and lower rail 13 are welded together with the roller 15 structural base, and then precision-machined. The roller 15 is then precisely disassembled, and residual welding stress is eliminated. The rails of the roller 15 undergo ultrasonic induction hardening treatment, resulting in a rigid and stable roller 15 structure that is lightweight and resistant to deformation. Simultaneously, the upper rail 1 and lower rail 13 exhibit high surface hardness and moderate hardness layer thickness, improving wear resistance and achieving stable operation and a long service life for the roller 15. By disassembling the roller 15 into three parts and using pins 3 for positioning and installation on the connecting plate 18 at the disassembly point and on the rails, the roller 15 is easy to transport and resistant to deformation during transport. This also facilitates subsequent high-precision assembly and installation, ensuring that the assembled roller 15 and rails possess excellent roundness and installation accuracy, meeting the requirements for stable operation.

[0116] The above description is a specific implementation of the embodiments of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A method for preparing a rolling ring for a gantry bucket wheel stacker-reclaimer, characterized in that, Includes the following steps: S1, according to the design requirements of the roller (15), cut the materials for each component of the roller (15); S2, the various components of the welding roller (15) are assembled to form a complete roller (15). S3, disassemble the complete roller (15) into three parts; S4, tempering is performed on each part of the disassembled roller (15) to eliminate residual welding stress; S5, after the disassembled roller (15) is reassembled into a circle, it is machined to make the track of the roller (15) meet the roundness requirements; S6, the track surface of the machined roller (15) is hardened; S7, assemble the hopper (16) to form a rolling ring; S8, the rolling ring is cleaned, sandblasted and painted; The components include an outer plate (8) for mounting the hopper (16), an inner plate (7) concentric with and located inside the outer plate (8), an upper ring plate (5) and a lower ring plate (10) surrounding the inner plate (7) and the outer plate (8), and an upper rail (1) and a lower rail (13) located at the lower part of the upper ring plate (5) and the lower ring plate (10) and at the lower ends of the inner plate (7). The upper track (1) and lower track (13) are made of 45# steel plate and their chemical composition is re-inspected. The thickness and width of the 45# steel plate should be reserved for machining allowance. The shrinkage of welding should be considered when cutting the upper ring plate (5) and lower ring plate (10). S2 includes: S2.1, When assembling or stacking round tires on the platform, the flatness is ±1mm; S2.2, mark the ground, use a marking gauge to determine the inner and outer circles of the upper ring plate (5) and the lower ring plate (10) to ensure concentricity, and at the same time ensure that the track side diameter of the upper ring plate (5) and the lower ring plate (10) should be 6-8 mm larger than the design diameter; S2.3, with the lower ring plate (10) as the base, assemble the lower flange (12) plate according to the ground sample, and after splicing, level it and use a scribe to find the circle; S2.4, draw the assembly lines of the outer ring plate (8), inner ring plate (7), lower stiffener plate (11) and upper stiffener plate (4) on the lower ring plate (10); S2.5 After the outer plate (8) is cut, the square hole (19) for the installation of the hopper (16) is accurately marked on the outer plate (8) and cut intermittently; roll the outer plate (8) and the inner plate (7) and use a template to measure the roundness and correct it with flame until it meets the requirements of the drawing. When rolling the outer plate (8), the roundness diameter should be 6-8 mm larger than the design diameter; assemble the outer plate (8), the inner plate (7), the upper ring plate (5) and the lower stiffening plate (11) in sequence. S2.6, Assemble the lower rail (13) and the upper rail (1). The roundness of the upper rail (1) and the lower rail (13) needs to be corrected by flame until it meets the requirements of the drawing. When the lower rail (13) and the upper rail (1) are in a free state, the diameter of the rolled roundness should be 6-8 mm larger than the design diameter. The assembly gap is within 0-2 mm to ensure the flatness and roundness of the upper rail (1) and the lower rail (13). S2.7, accurately divide the circle and assemble the upper stiffening plate (4) and the upper flange (2), ensuring that the upper stiffening plate (4) is perpendicular to the upper flange (2) and spot welded to fix it; S2.8, after the upper stiffening plate (4) and the lower stiffening plate (11) are double-layered and reinforced, carbon dioxide gas shielded welding is used to weld each component; S2.9 After welding, inspect the verticality and roundness of the upper rail (1) and the lower rail (13).

2. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 1, characterized in that, The ellipticity and radial runout of the upper track (1) and the lower track (13) are not greater than 1.5 mm, the end face runout is not greater than 2.5 mm, and the outer circle ellipticity is not greater than 5 mm.

3. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 2, characterized in that, S3 includes: S3.1 Before disassembly, the roller (15) is under double-layer tension of the upper stiffening plate (4) and the lower stiffening plate (11). The overall dimensions of the roller (15) are checked, and the assembly line and disassembly line of the connecting plate (18) are marked. S3.2 When the roller (15) is disassembled, cut the roller (15) straight along the disassembly line. S3.3, cut the bucket hole along the square hole line of the hopper (16), and after disassembly, check the verticality of the upper track (1) and the lower track (13) as well as the chord length of each roller (15); S3.4 After the roller (15) is disassembled into three parts, the connecting plate (18) is assembled and welded at the disassembly port.

4. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 3, characterized in that, S4 includes: S4.1, place the three parts of the roller (15) flat in the heat treatment furnace respectively; S4.2, heat the temperature inside the heat treatment furnace to 630-650℃ and hold it for 3-4 hours, then cool it down with the furnace.

5. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 4, characterized in that, The heating rate of the heat treatment furnace is <80℃.

6. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 5, characterized in that, S5 includes: S5.1, Remove the upper stiffener plate (4) and lower stiffener plate (11) on the platform, and draw the alignment line of the connecting plate (18) group; S5.2, Machin the plane of the connecting plate (18) and mark the center line of the connecting plate hole, and drill the connecting plate hole with a jig; S5.3, the three parts of the disassembled roller (15) are rounded on a vertical lathe; S5.

4. Align with the track line, rough machine the track, and leave a 3-5mm machining allowance in the diameter direction after rough machining; when finishing the track, loosen the chuck appropriately to reduce the clamping force and ensure that the clamping force is uniform. S5.5, mark the center line of the pin hole and the pin hole line, drill the pin hole (14) and assemble the pin (3).

7. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 6, characterized in that, S6 includes: S6.1 After the upper track (1) and lower track (13) rolling rings after machining are inspected and qualified as a whole, the surfaces of the upper track (1) and lower track (13) are quenched. S6.2 After the quenching process is completed, check the surface hardness, roundness and perpendicularity of the upper track (1) and the lower track (13) to see if they meet the design standards.

8. The method for preparing the rolling ring of the gantry bucket wheel stacker-reclaimer according to claim 7, characterized in that, The quenching process adopts ultrasonic induction quenching. During the quenching process, the workpiece is rotated and a U-shaped quenching heating ring is made according to the shape of the upper track (1) and the lower track (13). The quenching temperature is 830-860℃. After quenching, water cooling is performed to make the surface harden rapidly and form martensitic structure. The surface hardness of the upper track (1) and the lower track (13) after quenching should reach HRC48~55 and the hardness layer depth is 3-4mm.

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