Manufacturing equipment for a lightweight plunger rod and manufacturing method thereof

Abstract

The present application relates to the technical field of metal material manufacturing, and particularly relates to a manufacturing device and a manufacturing method of a lightweight plunger rod, which aims to overcome the defects of complicated manufacturing and difficult-to-solve eccentric wear in the prior art, and is mainly realized by the following technical scheme: the manufacturing device of the lightweight plunger rod comprises a device chamber, a mounting clamp, a processing workpiece and a magnetic control workpiece, the mounting clamp, the processing workpiece and the magnetic control workpiece are all arranged in the device chamber, and a control console is further arranged; the manufacturing method of the lightweight plunger rod comprises steps of plunger rod manufacturing, cladding material preparation, laser cladding, impact strengthening, hardness inspection and magnetic control sputtering, the processing workpiece and the magnetic control workpiece are centrally arranged in the device chamber and avoid mutual interference through an isolation assembly, the manufacturing method simplifies the overall processing engineering, realizes lightweight manufacturing and processing of the plunger rod without changing the structure of the plunger rod, and improves manufacturing and processing efficiency.

Description

Technical Field

[0001] This invention relates to the field of metal material manufacturing technology, specifically to a lightweight plunger rod manufacturing equipment and manufacturing method. Background Technology

[0002] Currently, ultra-high pressure plunger pumps are mainly used in the marine engineering field, specifically in the rust removal process on ship surfaces. The plunger rod, as a core component of the ultra-high pressure plunger pump, is crucial to the pump's operating efficiency and the progress of the rust removal operation. Existing ultra-high pressure plunger pump plunger rods are mostly made of cemented carbide, which has high overall hardness and is difficult to machine, thus inevitably resulting in some defects on the workpiece surface. Furthermore, the ultra-high pressure plunger rods currently in use are quite heavy, and under the influence of gravity during operation, they are prone to uneven wear with the plunger cylinder liner. Prolonged operation in ultra-high pressure and high-speed environments can cause these defects to further develop into cracks, severely reducing the plunger rod's service life. Therefore, it is necessary to manufacture the plunger rod in a lightweight manner while ensuring its usability, effectively solving the problem of uneven wear.

[0003] Chinese patent CN106439003A discloses a lightweight piston rod. This piston rod has a cross-shaped cross section and four concave grooves symmetrically formed along the axial direction of the rod on its side. Although this application reduces the weight of the piston rod through structural design, it affects the load-bearing capacity of the piston rod and is not suitable for the field of marine piston pumps in high-pressure and complex environments. Chinese patent CN102501026A discloses a method for manufacturing a piston rod covered with a stainless steel plate. By covering the outside of the piston rod with a layer of stainless steel plate, it solves the problems of piston rod strength and corrosion resistance and improves the wear resistance of the piston rod. However, this application transfers the uneven wear to the coating layer and does not effectively reduce uneven wear.

[0004] Therefore, there is a need for manufacturing equipment and methods that can manufacture the plunger rod in a lightweight manner and reduce wear without changing its original structure, while also simplifying the manufacturing process and ensuring the surface strength of the plunger rod. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the defects of the prior art, which is cumbersome to manufacture and difficult to solve the problem of uneven wear, so as to provide a manufacturing equipment and manufacturing method for a lightweight plunger rod.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0007] A manufacturing apparatus for a lightweight plunger rod includes a cylindrical equipment chamber, a frame disposed below the equipment chamber, a working cavity disposed inside the equipment chamber, an operating door hinged to the front side of the equipment chamber, and a control console disposed outside the equipment chamber, the control console being signal-controlled connected to the equipment chamber, and further includes:

[0008] The mounting fixtures are arranged opposite each other at both ends of the working cavity. The mounting fixtures include an upper fixture and a lower fixture. The upper fixture is rotatably mounted on the top of the working cavity, and the lower fixture is rotatably mounted on the bottom of the working cavity. The bottom of the lower fixture extends out of the equipment room and is connected to a rotating component. The rotating component includes a transmission gear, a rotating gear, and a rotating motor. The transmission gear is coaxially arranged with the lower fixture and fixed at the bottom of the lower fixture. The rotating gear meshes with the transmission gear. The rotating gear is also sleeved on the output shaft of the rotating motor. The rotating motor is mounted on the frame.

[0009] The machined workpiece is installed in a working cavity. The workpiece includes a cladding workpiece and an impact workpiece arranged opposite each other. Vertical cladding tracks and impact tracks are respectively provided in the working cavity corresponding to the cladding workpiece and the impact workpiece. The cladding tracks and impact tracks are both arranged along the axis of the working cavity and fixed to the inner side wall of the equipment. The cladding workpiece includes a cladding drive, a cladding element, and a cladding cable. The cladding drive controls the cladding element to slide on the cladding track. One end of the cladding cable is connected to the cladding element and slides vertically with the cladding element, and the other end extends out of the equipment. The impact workpiece includes an impact drive, an impact element, and a power cord. The impact drive controls the impact element to slide on the impact track. One end of the power cord is connected to the impact element and slides vertically with the impact element, and the other end extends out of the equipment. An impact power supply is provided outside the equipment and connected to the power cord.

[0010] A magnetically controlled workpiece is disposed within a working cavity. The magnetically controlled workpiece includes an operating target and an isolation assembly. Multiple operating targets are arranged in a circumferential array and installed on the inner side wall of the equipment. The isolation assembly is disposed near the top of the working cavity and includes two oppositely arranged movable isolations and two oppositely arranged fixed isolations. The movable isolations are correspondingly disposed on the top of the cladding workpiece, and the fixed isolations are arc-shaped and oppositely disposed within the working cavity.

[0011] By adopting the above technical solution, this application realizes cladding, ultrasonic impact, and magnetron sputtering operations indoors, eliminating the need for mid-process equipment updates or material transfers. This achieves centralized processing and, compared to existing equipment, shortens production time, increases production efficiency, and improves processing quality. During use, cladding and ultrasonic impact can be performed synchronously or asynchronously, allowing for timely detection and processing of the cladding layer. This results in good feedback, high processing timeliness, and higher quality of the manufactured plunger rods. The control console is connected to the signal control of the workpieces being processed—clad, impacted, and magnetron sputtered—effectively enhancing operational intelligence and enabling automated production. The isolation component above the target material effectively prevents interference and damage to the workpieces during magnetron sputtering, extending the equipment's lifespan.

[0012] Furthermore, the upper clamp includes an upper jaw disc, three upper jaws, and an upper jaw drive. The upper jaw drive is disposed within the upper jaw disc and controls the three upper jaws to move radially relative to each other along the upper jaw disc. The lower clamp includes a lower jaw disc, three lower jaws, and a lower jaw drive. The lower jaw drive is disposed within the lower jaw disc and controls the three lower jaws to move radially relative to each other along the lower jaw disc. A rolling bearing is also fitted near the bottom outer wall of the lower jaw disc. The rolling bearing is keyed to the lower jaw disc and is rotatably mounted at the bottom of the equipment chamber.

[0013] By adopting the above technical solution, the upper and lower clamps work together to clamp the machined plunger rod. The mounting clamp, together with the rotating part at the bottom, enables the workpiece to be positioned and rotated, thereby allowing the workpiece's circumferential motion to cooperate with the axial sliding of the workpiece, thus achieving the surface coating work of the plunger rod.

[0014] Furthermore, the cladding component includes a cladding operating arm, a cladding head, and a cladding slider. The cladding operating arm is a telescopic structure and is arranged radially along the equipment chamber. A cladding head is fixed to one end of the cladding operating arm near the center of the equipment chamber, and a cladding slider is fixed to the other end of the cladding operating arm. The cladding slider is slidably positioned within the cladding track by a cladding drive control. The cladding cable includes a powder feeding channel, a cladding component power line, and an optical fiber. The cladding cable passes through the cladding slider and extends out of the equipment chamber along the cladding track. An operating device is also provided outside the equipment chamber and connected to the cladding cable. The operating device includes a powder feeder, a cladding power supply, and a laser emitter. The other end of the powder feeding channel is connected to the powder feeder, the other end of the cladding component power line is connected to the cladding power supply, and the other end of the optical fiber is connected to the laser emitter.

[0015] By adopting the above technical solution, the cladding head moves up and down with the cladding slider to realize the cladding operation on the surface of the plunger rod. The extension and retraction of the cladding operating arm can perform surface cladding according to plunger rods of different diameters. The operating equipment provides power, laser and powder feeding support for the cladding part.

[0016] Furthermore, the equipment chamber has a through hole corresponding to the cladding cable, and a sealing element is provided at the through hole. The sealing element includes a sealing ring and an expansion ring. The sealing ring is snapped into the through hole, and the expansion ring extends onto the sealing ring with a through hole in the middle. The expansion ring is located on the side of the sealing ring away from the equipment chamber. The top of the cladding track has two vertically parallel guide wheels corresponding to the cladding cable. The axis of the guide wheels is set along the width direction of the cladding track and is rotatably mounted in the equipment chamber. The cladding slider is also rotatably mounted on the side of the cladding track. The axis of the guide wheels is also set along the width direction of the cladding track. There are shielding plates arranged opposite each other in the cladding track. The shielding plates are set along the length direction of the cladding track and their width is less than half the width of the cladding track. A gap is left between the two shielding plates.

[0017] By adopting the above technical solution, the powder feeder, cladding power supply and laser emitter are combined into one cable to support the cladding part and are connected to the equipment room through the through hole, reducing the contact between the equipment room and the outside world and ensuring internal sealing and stable air pressure; the guide wheel and the wire feeding wheel ensure stable wire feeding and avoid the wire from getting tangled when the cladding operating arm slides up and down, which would affect the cladding process; the shielding plate shields part of the cladding track, reducing the impact of slippage and preventing impurities and dust from splashing into the cladding track.

[0018] Furthermore, an adjustment component is provided between the operating device and the equipment room. The cladding cable is wound around the adjustment component. The adjustment component includes an adjustment frame, an adjustment drive, multiple guide wheels and sliding wheels. The guide wheels and sliding wheels are all rotatably mounted on the adjustment frame. The guide wheels are arranged in pairs and are located on both sides of the sliding wheels. The sliding wheels are also controlled by the adjustment drive to be raised and lowered on the adjustment frame. The adjustment frame has a sliding groove for the sliding wheels to slide.

[0019] By adopting the above technical solution, since there are many wires wrapped around the cladding cable, an adjustment component is set to facilitate the smooth sliding of the cladding cable up and down, realize the sorting operation of the cladding cable, avoid the situation of the wires being tangled and messy, and also avoid safety accidents caused by the wires being crossed and pulled.

[0020] Furthermore, the impact component includes an impact operating arm, an impact head, and an impact slider. The impact operating arm is a telescopic structure and is arranged radially along the equipment chamber. An impact head is fixed at one end of the impact operating arm near the center of the equipment chamber, and an impact slider is fixed at the other end of the impact operating arm. A through hole is also provided on the equipment chamber corresponding to the power line, and a sealing element is provided at the through hole. Limiting plates are arranged opposite each other in the impact track. The limiting plates are arranged along the length direction of the impact track and their width is less than half the width of the impact track. A gap is left between the two limiting plates.

[0021] By adopting the above technical solution, the sealing component seals the through hole, reducing the interference of the external environment on the equipment room, and the limiting plate also protects the impact rail.

[0022] Furthermore, the two movable isolations are connected by a telescopic drive with double-ended output shafts. Each movable isolation includes two oppositely arranged isolation plates and an isolation drive. The isolation drive controls the relative movement of the two isolation plates. The isolation plates have clearance notches corresponding to the cladding track and the impact track. The two isolation plates are engaged at their opposite positions and the isolation plates are movably arranged above the fixed isolation. The fixed isolation also has a limiting card extending from it. The limiting card is arranged radially along the fixed isolation and is arranged opposite to each other on the top two sides of the fixed isolation.

[0023] Furthermore, each of the isolation drives includes two drive gears and a drive rack. The drive rack is meshed with the two drive gears on both sides. The drive gears are mounted on the isolation plate and drive the isolation plate to move. The drive rack is located in the middle of the two isolation plates and slides laterally above the fixed isolation plate. The drive rack is controlled by a telescopic drive with a double-ended output shaft.

[0024] By adopting the above technical solution, taking the movable isolation on the left as an example, under normal circumstances, the movable isolation is open and does not affect the cladding operation. After the cladding and impact operations are completed, the cladding workpiece and the impact workpiece are both raised and stored at the top of the equipment chamber. At this time, the output axes of the two ends of the telescopic drive are controlled to move closer to the center side, thereby pushing the drive rack on the left to the right, causing the two isolation plates to move closer to each other until the clearance notch is in contact with the cladding track and the sides of the two isolation plates are in contact, completing the closing operation. At this time, the magnetron sputtering operation is performed to avoid affecting the cladding workpiece and the impact workpiece during magnetron sputtering, and to avoid reducing their service life.

[0025] A method for manufacturing a lightweight plunger rod, characterized in that: the manufacturing equipment applicable to the lightweight plunger rod described in any one of claims 1-8 includes:

[0026] S1. Plunger rod manufacturing: The plunger rod core is composed of the following components by weight percentage: chromium 0.5-1.5%, iron 0.5-1.5%, aluminum 4.4-5.7%, molybdenum 4.0-5.5%, titanium 85.8-90.6%. After melting and casting, it is machined to the required size and the surface is machined and polished.

[0027] S2. Preparation of cladding materials: The cladding layer powder is nickel-aluminum alloy powder. The mass ratio of nickel-aluminum alloy powder is: aluminum 28.8-36.1%, chromium 19-23%, iron 3.2-9.3%, molybdenum 5.7-10%, nickel 28.9%-36%. The particle size range of Al powder is between 100 and 200 mesh, and the particle size range of Ni powder is between 150 and 250 mesh.

[0028] S3. Laser cladding: The plunger rod to be processed is installed in the working cavity and rotated circumferentially by a fixed fixture. The workpiece to be clad moves axially on the outside of the plunger rod until the entire surface of the plunger rod is clad. The laser power is 2200W, the spot diameter is 4mm, the overlap rate is 50%, the scanning speed is 0.007m / s, the powder feeding speed is 12g / min, nitrogen protection is used during the laser cladding process, the protective gas flow rate is 15L / min, and the cladding layer thickness is 4mm.

[0029] S4. Impact strengthening: The plunger rod to be processed is installed in the working cavity and rotated in a circular motion by a fixed fixture. The impact workpiece moves axially on the outside of the plunger rod. The ultrasonic impact parameters are adjusted to ultrasonically treat the laser cladding layer to eliminate residual stress in the cladding layer. The hardness of the laser cladding transition layer is adjusted to be 0.6 to 0.65 of the hardness span between the substrate and the magnetron sputtering layer. The hardness after ultrasonic impact strengthening is used to verify the selected nickel-aluminum alloy powder ratio and the laser cladding and ultrasonic impact process parameters.

[0030] S5. Use nanoindentation technology to examine the change in hardness of the cladding layer and verify the strengthening effect of ultrasonic impact. If the strengthening effect meets the requirements, determine the alloy powder ratio and cladding and ultrasonic parameters in S2-S4. If the strengthening effect does not meet the requirements, repeat steps S2-S4 and readjust the alloy powder ratio and cladding and ultrasonic process parameters.

[0031] S6. Magnetron sputtering: A thin film is deposited on the cladding layer to further improve the surface hardness to 1000 HV. The magnetron sputtering parameters are controlled as follows: bias voltage -180V, temperature 25℃, gas flow rate 140sccm, current 6.5A, sputtering target is a high-entropy alloy target, working gas is Ar and N2, where N2:Ar is 0.5, target-substrate distance is 130mm, duty cycle is 50%, and the atomic fraction of the target material is: copper 11.2%, cobalt 22.2%, chromium 22.2%, iron 22.8%, nickel 22.8%.

[0032] By adopting the above technical solution, this application first prepares the plunger rod core using a lightweight alloy material and then machines it. Next, a cladding layer is processed on the surface of the plunger rod core using laser cladding equipment. During the laser cladding process, residual stress in the cladding layer is continuously strengthened and eliminated through ultrasonic impact, enhancing the surface hardness of the plunger rod after laser cladding. Finally, a magnetron sputtering film is deposited on the cladding layer using magnetron sputtering to further improve the surface hardness of the plunger rod, completing the plunger rod manufacturing. This application improves the comprehensive performance of the plunger rod, including hardness, toughness, and strength. The product meets the complex environment requirements of ultra-high pressure plunger pumps without altering the plunger rod structure, effectively reducing the manufacturing cost of the plunger rod.

[0033] Furthermore, before the magnetron sputtering operation, a glow discharge sputtering pretreatment of 15-20 minutes is performed to clean the target material. During the cleaning process, the target current is set to 4A, the negative bias voltage is -240V, and the duration is 15-20 minutes.

[0034] By adopting the above technical solution, the target material is cleaned through glow discharge sputtering pretreatment, which facilitates the bonding of the thin film and cladding layer generated by magnetron sputtering operation.

[0035] In summary, the technical solution of the present invention has the following advantages:

[0036] 1. The lightweight plunger rod manufacturing equipment provided by this invention realizes cladding operation, ultrasonic impact and magnetron sputtering in the equipment room, without the need for mid-process equipment replacement or material transfer, and can achieve the purpose of centralized processing. Compared with existing equipment, it can shorten production time, improve production efficiency and improve processing quality. When in use, the cladding operation and ultrasonic impact can be carried out synchronously or asynchronously, with high processing timeliness and higher quality plunger rod manufacturing.

[0037] 2. The lightweight plunger rod manufacturing equipment provided by the present invention can effectively avoid interference and damage to the workpiece during magnetron sputtering by setting an isolation component above the operating target, thereby improving the service life of the equipment.

[0038] 3. The lightweight plunger rod manufacturing method provided by the present invention involves manufacturing a cladding layer by laser cladding, strengthening the cladding layer by ultrasonic impact, and then adding a magnetron sputtering process to form a magnetron sputtering thin film. The composite layer formed by the cladding layer and the magnetron sputtering thin film has good bonding force, which meets the requirements for use of plunger rods in ultra-high pressure marine plunger pumps. At the same time, the introduced weight is negligible, achieving the purpose of lightweight manufacturing and reducing wear.

[0039] 4. The manufacturing method of the lightweight plunger rod provided by the present invention achieves an optimal hardness gradient by adjusting the powder ratio of the cladding layer so that the hardness value of the laser cladding layer is located at 0.6 to 0.65 of the hardness span between the substrate and the magnetron sputtering layer, and by adjusting the surface hardness of the laser cladding layer to 0.6 to 0.63 of the hardness span between the cladding layer and the magnetron sputtering layer through ultrasonic impact, thereby making the prepared composite layer less prone to cracking. Attached Figure Description

[0040] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0041] Figure 1This is a schematic diagram of the overall structure of a lightweight plunger rod manufacturing equipment provided in one embodiment of the present invention;

[0042] Figure 2 A cross-sectional view of a manufacturing apparatus for a lightweight plunger rod provided in one embodiment of the present invention;

[0043] Figure 3 This is a schematic diagram of the internal structure of the equipment room provided in one embodiment of the present invention;

[0044] Figure 4 This is a partial structural schematic diagram of a magnetically controlled workpiece provided in one embodiment of the present invention;

[0045] Figure 5 A flowchart illustrating a method for manufacturing a lightweight plunger rod according to one embodiment of the present invention;

[0046] Figure 6 Microstructure of magnetron sputtered thin films on the surface of cladding layers with different aluminum contents;

[0047] Figure 7 Comparison of cross-sectional microstructures for magnetron sputtering operations with different hardness gradients.

[0048] Explanation of reference numerals in the attached figures:

[0049] 1. Equipment room; 11. Frame; 12. Working chamber; 13. Cladding track; 131. Wire guide wheel; 132. Wire feed wheel; 133. Shielding plate; 14. Impact track; 141. Limiting plate; 15. Operating door; 16. Through hole; 17. Sealing element; 171. Sealing ring; 172. Expansion ring; 1721. Through hole; 2. Control console; 3. Mounting fixture; 31. Upper fixture; 311. Upper jaw. 312. Disc body; 313. Upper jaw body; 32. Upper jaw drive; 32. Lower clamp; 321. Lower jaw disc body; 3211. Rolling bearing; 322. Lower jaw body; 323. Lower jaw drive; 33. Rotating component; 331. Transmission gear; 332. Rotating gear; 333. Rotating motor; 4. Workpiece being machined; 41. Workpiece being clad; 412. Cladding component; 4121. Cladding operating arm; 4122. 4123. Cladding head; 413. Cladding slider; 413. Cladding cable; 4131. Powder feeding channel; 4132. Cladding component power cord; 4133. Optical fiber; 42. Impact workpiece; 422. Impact component; 4221. Impact operating arm; 4222. Impact head; 4223. Impact slider; 423. Power cord; 5. Magnetically controlled workpiece; 51. Operating target; 52. Isolation assembly; 521. Movable isolation; 5211. Isolation plate; 52111. Clearance notch; 5212. Isolation drive; 52121. Drive gear; 52122. Drive rack; 522. Fixed isolation; 5221. Limiting card; 6. Operating equipment; 61. Powder feeder; 62. Cladding power supply; 63. Laser emitter; 7. Adjusting component; 71. Adjusting frame; 711. Sliding groove; 72. Adjustment drive; 73. Guide wheel; 74. Sliding wheel. Detailed Implementation

[0050] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention.

[0051] A manufacturing device for lightweight plunger rods, such as Figure 1 and Figure 2 As shown, the system includes an equipment room 1, a mounting fixture 3, a workpiece 4 to be processed, and a magnetically controlled workpiece 5. The mounting fixture 3, workpiece 4, and magnetically controlled workpiece 5 are all located within the equipment room 1. A control console 2 is also included. This application enables cladding, ultrasonic impact, and magnetron sputtering operations within the equipment room 1, eliminating the need for mid-process equipment updates or material transfers. This centralized processing achieves faster production time, higher efficiency, and improved processing quality compared to existing equipment. The control console 2 is connected to the workpiece 4 (cladding workpiece 41, impact workpiece 42, and magnetically controlled workpiece 5) via signal control, further enhancing operational intelligence and enabling automated production.

[0052] like Figure 1 and Figure 2As shown, the mounting fixture 3 is positioned opposite each other at the upper and lower ends of the working cavity 12. The mounting fixture 3 includes an upper fixture 31 and a lower fixture 32. The upper fixture 31 is rotatably mounted on the top end of the working cavity 12, and the lower fixture 32 is rotatably mounted on the bottom end of the working cavity 12. The upper fixture 31 includes an upper jaw disc 311, three upper jaw bodies 312, and an upper jaw drive 313. The upper jaw drive 313 is located inside the upper jaw disc 311 and controls the three upper jaw bodies 312 to move radially relative to each other along the upper jaw disc 311. The upper jaw drive 313 includes multiple upper bevel gears, a gear disk, and a helical track. The upper bevel gears mesh with the gear disk, and the upper jaw bodies 312 engage with the helical track. When one of the upper bevel gears is rotated, it drives the gear disk to rotate, thereby causing the helical track fixed to the gear disk to rotate as well. This causes the upper jaw bodies 312 to slide along the radial groove on the surface of the upper jaw disc 311, realizing the clamping and releasing of the upper fixture 31.

[0053] The lower clamp 32 includes a lower jaw disc 321, three lower jaw bodies 322, and a lower jaw drive 323. The lower jaw drive 323 is located inside the lower jaw disc 321 and controls the three lower jaw bodies 322 to move radially relative to each other along the lower jaw disc 321. A rolling bearing 3211 is also fitted near the bottom outer wall of the lower jaw disc 321. The rolling bearing 3211 is keyed to the lower jaw disc 321 and is rotatably mounted at the bottom of the equipment chamber 1. The working principle of the lower clamp 32 is the same as that of the upper clamp 31.

[0054] like Figure 2 and Figure 3 As shown, the bottom of the lower clamp 32 extends out of the equipment chamber 1 and is connected to a rotating component 33. The rotating component 33 includes a transmission gear 331, a rotating gear 332, and a rotating motor 333. The transmission gear 331 is coaxially arranged with the lower clamp 32 and fixed to the bottom of the lower clamp 32. The rotating gear 332 meshes with the transmission gear 331 and is also sleeved on the output shaft of the rotating motor 333. The rotating motor 333 is mounted on the frame 11. The mounting clamp 3, in conjunction with the rotating component 33 at the bottom, enables the workpiece to be positioned and rotated, thereby allowing the workpiece to move circumferentially to coordinate with the axial sliding of the workpiece 4, thus achieving the surface coating work of the plunger rod.

[0055] like Figure 1 , Figure 2 and Figure 3As shown, the workpiece 4 is installed in the working chamber 12. The workpiece 4 includes a cladding workpiece 41 and an impact workpiece 42 arranged opposite to each other. Vertical cladding tracks 13 and impact tracks 14 are respectively provided in the working chamber 12 corresponding to the cladding workpiece 41 and the impact workpiece 42. The cladding tracks 13 and impact tracks 14 are both arranged along the axis of the working chamber 12 and fixed to the inner side wall of the equipment chamber 1. The cladding workpiece 41 includes a cladding drive, a cladding element 412 and a cladding cable 413. The cladding drive (not shown in the figure) controls the cladding element 412 to slide on the cladding track 13. One end of the cladding cable 413 is connected to the cladding element 412 and slides vertically with the cladding element 412, and the other end extends out of the equipment chamber 1.

[0056] The impact workpiece 42 includes an impact drive, an impact member 422, and a power line 423. The impact drive (not shown in the figure) controls the impact member 422 to slide on the impact track 14. One end of the power line 423 is connected to the impact member 422 and slides vertically with the impact member 422, while the other end extends out of the equipment chamber 1. An impact power supply is provided outside the equipment chamber 1 and connected to the power line 423.

[0057] like Figure 1 , Figure 2 and Figure 3 As shown, the cladding component 412 includes a cladding operating arm 4121, a cladding head 4122, and a cladding slider 4123. The cladding operating arm 4121 is a telescopic structure and is arranged radially along the equipment chamber 1. The cladding head 4122 is fixed at one end of the cladding operating arm 4121 near the center of the equipment chamber 1, and the cladding slider 4123 is fixed at the other end of the cladding operating arm 4121. The cladding slider 4123 is slidably positioned within the cladding track 13 by a cladding drive control. The cladding head 4122 slides up and down with the cladding slider 4123 to perform cladding operations on the surface of the plunger rod. The extension and retraction of the cladding operating arm 4121 can perform surface cladding according to plunger rods of different diameters. A baffle plate 133 is arranged opposite each other within the cladding track 13. The baffle plate 133 is arranged along the length of the cladding track 13 and its width is less than half the width of the cladding track 13, with a gap between the two baffle plates 133. The shielding plate 133 partially shields the cladding track 13, reducing the impact of slippage and preventing impurities and dust from splashing into the cladding track 13.

[0058] The cladding cable 413 includes a powder feeding channel 4131, a cladding component power cable 4132, and an optical fiber 4133. The cladding cable 413 passes through the cladding slider 4123 and extends out of the equipment chamber 1 along the cladding track 13. An operating device 6 is also installed outside the equipment chamber 1 and connected to the cladding cable 413. The operating device 6 includes a powder feeder 61, a cladding power supply 62, and a laser emitter 63. The other end of the powder feeding channel 4131 is connected to the powder feeder 61, the other end of the cladding component power cable 4132 is connected to the cladding power supply 62, and the other end of the optical fiber 4133 is connected to the laser emitter 63. The operating device 6 provides power, laser, and powder feeding support to the cladding component 412.

[0059] Two vertically arranged guide rollers 131 are provided at the top of the cladding track 13 corresponding to the cladding cable 413. The axis of the guide rollers 131 is set along the width direction of the cladding track 13, and both ends are rotatably mounted in the equipment chamber 1. A wire feeding roller 132 is also rotatably mounted at the bottom of the cladding slider 4123 near the side of the cladding track 13. The axis of the wire feeding roller 132 is also set along the width direction of the cladding track 13. The cladding cable 413 passes between the wire feeding roller 132 and the two guide rollers 131 and passes through the through hole 16 to extend out of the outside of the equipment chamber 1.

[0060] like Figure 2 and Figure 3 As shown, the impact component 422 includes an impact operating arm 4221, an impact head 4222, and an impact slider 4223. The impact operating arm 4221 is a telescopic structure and is arranged radially along the equipment chamber 1. The impact head 4222 is fixed to one end of the impact operating arm 4221 near the center of the equipment chamber 1, and the impact slider 4223 is fixed to the other end of the impact operating arm 4221. Similar to the cladding component 412, the impact component 422 is driven by a slider to achieve axial movement. Limiting plates 141 are arranged opposite each other inside the impact track 14. The limiting plates 141 are arranged along the length direction of the impact track 14 and their width is less than half the width of the impact track 14. A gap is left between the two limiting plates 141, and the limiting plates 141 also protect the impact track 14.

[0061] like Figure 2 As shown, a through hole 16 is provided on the equipment chamber 1 corresponding to the cladding cable 413. A sealing element 17 is provided at the through hole 16. The sealing element 17 includes a sealing ring 171 and an expansion ring 172. The sealing ring 171 is snapped into the through hole 16, and the expansion ring 172 extends onto the sealing ring 171 with a through hole 1721 in the middle. The expansion ring 172 is located on the side of the sealing ring 171 away from the equipment chamber 1. The powder feeder 61, the cladding power supply 62, and the laser emitter 63 are combined into a single cable to support the cladding element 412 and are connected to the equipment chamber 1 through the through hole 16, reducing the contact between the equipment chamber 1 and the outside world and ensuring internal sealing and stable air pressure. A through hole 16 is also provided on the equipment chamber 1 corresponding to the power line 423, and a sealing element 17 is provided at the through hole 16. The sealing element 17 seals the through hole 16, reducing the interference of the external environment on the interior of the equipment chamber 1.

[0062] like Figure 1 and Figure 2As shown, an adjustment component 7 is also provided between the operating device 6 and the equipment room 1. The cladding cable 413 is wound around the adjustment component 7. The adjustment component 7 includes an adjustment frame 71, an adjustment drive 72, four guide wheels 73, and a sliding wheel 74. The guide wheels 73 and the sliding wheels 74 are all rotatably mounted on the adjustment frame 71. Two pairs of vertically arranged guide wheels 73 are located on the left and right sides above the sliding wheels 74. The sliding wheels 74 are also controlled by the adjustment drive 72 to be raised and lowered on the adjustment frame 71. The adjustment frame 71 has a sliding groove 711 for the sliding wheels 74 to slide. The cladding cable 413 first passes between the pair of guide wheels 73 on the right side and wound around the bottom of the sliding wheels 74, and then passes between the pair of guide wheels 73 on the left side before being connected to the operating device 6. Since there are many wires wound around the cladding cable 413, the adjustment component 7 is set up to facilitate the smooth up and down sliding of the cladding cable 413, realize the sorting operation of the cladding cable 413, avoid the situation of the wires being tangled and messy, and also avoid the safety accidents caused by the wires crossing and pulling.

[0063] like Figure 2 , Figure 3 and Figure 4 As shown, the magnetically controlled workpiece 5 is disposed in the working cavity 12. The magnetically controlled workpiece 5 includes an operating target 51 and an isolation component 52. Multiple operating targets 51 are disposed in a circumferential array and installed on the inner side wall of the equipment chamber 1. The isolation component 52 is disposed in the working cavity 12 near the top. The isolation component 52 includes two horizontally opposite movable isolations 521 and two vertically opposite fixed isolations 522. The movable isolations 521 are disposed on the top of the cladding workpiece 41, and the fixed isolations 522 are arc-shaped and disposed opposite each other in the working cavity 12.

[0064] The two movable isolations 521 are connected by a telescopic drive with double-ended shafts. Each movable isolation 521 includes two isolation plates 5211 arranged in opposite directions and an isolation drive 5212. The isolation drive 5212 controls the two isolation plates 5211 to rotate relative to each other and move closer or further away. The isolation plates 5211 have clearance notches 52111 on them corresponding to the cladding track 13 and the impact track 14. The two isolation plates 5211 are engaged at their opposite positions and the isolation plates 5211 are movably arranged above the fixed isolation 522. The fixed isolation 522 also has a limiting card 5221 extending from it. The limiting card 5221 is arranged radially along the fixed isolation 522 and is arranged opposite to each other on the top two sides of the fixed isolation 522. Each isolation drive 5212 includes two drive gears 52121 and a drive rack 52122. The drive rack 52122 is meshed with the two drive gears 52121 on both sides respectively. The drive gears 52121 are mounted on the isolation plate 5211 and drive the isolation plate 5211 to move. The drive rack 52122 is located in the middle of the two isolation plates 5211 and is laterally slidable above the fixed isolation 522. The drive rack 52122 is controlled by a telescopic drive with a double-ended output shaft.

[0065] A method for manufacturing a lightweight plunger rod, applicable to the aforementioned manufacturing equipment for a lightweight plunger rod, such as... Figure 5 As shown, the process includes: S1, plunger rod manufacturing, the plunger rod core is composed of the following components by weight percentage: chromium 0.5-1.5%, iron 0.5-1.5%, aluminum 4.4-5.7%, molybdenum 4.0-5.5%, titanium 85.8-90.6%, after casting, it is machined to the required dimensions and the surface is machined and polished; S2, cladding material preparation, the cladding layer powder is selected from nickel-aluminum alloy powder, the mass ratio of nickel-aluminum alloy powder is: aluminum 28.8-36.1%, chromium 19-23%, iron 3.2-9.3%, molybdenum 5.7-10%, nickel 28.9%-36%, and the Al powder particle size range is between 100 and 200 mesh. Ni powder particle size ranges from 150 to 250 mesh; S3, laser cladding: the plunger rod to be processed is installed in the working cavity 12 and rotated circumferentially by a fixed fixture, while the cladding workpiece 41 moves axially outside the plunger rod until the entire surface of the plunger rod is clad; laser power 2200W, spot diameter 4mm, overlap rate 50%, scanning speed 0.007m / s, powder feeding speed 12g / min, nitrogen protection is used during laser cladding, protective gas flow rate 15L / min, and the cladding layer thickness is 4mm; S4, impact strengthening: the plunger rod to be processed is installed in the working cavity 12 and rotated circumferentially by a fixed fixture. The piston rod rotates in a circular motion, causing the workpiece 42 to move axially outside the piston rod. Ultrasonic impact parameters are adjusted to ultrasonically treat the laser cladding layer, eliminating residual stress and adjusting the hardness of the laser cladding transition layer to 0.6–0.65 of the hardness difference between the substrate and the magnetron sputtering layer. The hardness after ultrasonic impact strengthening is used to verify the selected nickel-aluminum alloy powder ratio and the laser cladding and ultrasonic impact process parameters. S5: Using nanoindentation technology, the hardness change of the cladding layer is examined to verify the strengthening effect of ultrasonic impact. If the strengthening effect meets the requirements, the alloy powder ratio and cladding and ultrasonic parameters in S2–S4 are determined; if the strengthening effect is not satisfactory... If the requirements are met, repeat steps S2-S4, readjusting the alloy powder ratio and cladding and ultrasonic process parameters; S6, magnetron sputtering, depositing a thin film on the cladding layer to further improve the surface hardness to 1000HV, adjusting the magnetron sputtering parameters: bias voltage -180V, temperature 25℃, gas flow rate 140sccm, current 6.5A, sputtering target is a high-entropy alloy target, working gas is Ar and N2, where N2:Ar is 0.5, target-substrate distance is 130mm, duty cycle is 50%, target atomic fraction ratio is: copper 11.2%, cobalt 22.2%, chromium 22.2%, iron 22.8%, nickel 22.8%.

[0066] Before the magnetron sputtering operation, a glow discharge sputtering pretreatment of 15-20 minutes is performed to clean the target material. During the cleaning process, the target current is set to 4A, the negative bias voltage is -240V, and the duration is 15-20 minutes.

[0067] First, the plunger rod core is prepared using a lightweight alloy material and machined. Then, an alloy powder is used to laser alloy the plunger rod surface to form a cladding layer. During the laser cladding process, ultrasonic impact is used to continuously strengthen and eliminate residual stress in the cladding layer, thereby enhancing the surface hardness of the plunger rod after laser cladding. Finally, magnetron sputtering is used to deposit a magnetron sputtered thin film on the cladding layer to further improve the surface hardness of the plunger rod, completing the plunger rod manufacturing. This application improves the comprehensive performance of the plunger rod, including hardness, toughness, and strength. The product meets the complex environment of ultra-high pressure plunger pumps without changing the plunger rod structure, effectively reducing the manufacturing cost of the plunger rod.

[0068] like Figure 5 , Figure 6 and Figure 7 As shown, magnetron sputtered films on the cladding layer surface with different aluminum contents exhibit different micromorphologies. In a, the aluminum content of the cladding layer powder is 10%–25%, and agglomeration occurs. In b, the aluminum content of the cladding layer powder is 25%–40%, resulting in uniform deposition and a relatively smooth surface. In c, the aluminum content of the cladding layer powder is >40%, leading to increased agglomeration. Therefore, this application selects an appropriate proportion of aluminum content to achieve high performance of the magnetron sputtered film on the cladding layer surface, ensuring the overall quality of the subsequent plunger rod.

[0069] In step d, magnetron sputtering was performed without ultrasonic impact to control the hardness of the cladding transition layer, resulting in a gap between the magnetron sputtered film and the cladding layer. In step e, magnetron sputtering was performed after ultrasonic impact to control the hardness of the cladding transition layer, resulting in a good bond between the magnetron sputtered film and the cladding layer. Incorporating an ultrasonic impact step effectively improves the manufacturing quality of the plunger rod and ensures its quality.

[0070] According to the wear calculation, the wear amount of the plunger rod prepared in this application is only 0.156 times that of a conventional plunger rod. However, this is the result under the condition that the wear efficiency remains unchanged. In reality, due to the presence of aluminum in the cladding layer, nitrogen atoms are deposited during magnetron sputtering, and the deposited film is smooth and flat, which reduces the wear efficiency and can further reduce the wear amount of the plunger rod of this invention.

[0071] The working principle and usage of the lightweight plunger rod manufacturing equipment are as follows: The machined plunger rod is installed in the mounting fixture 3, and the upper fixture 31 and lower fixture 32 are clamped according to the diameter of the plunger rod; the cladding workpiece 41 is started to perform the cladding operation, and the impact workpiece 42 is started at certain intervals or simultaneously to operate on the surface of the plunger rod; after the cladding and impact operations are completed, the cladding workpiece 41 and the reconstructed part are stored in the top of the equipment chamber 1, the isolation component 52 isolates the bottom from the top, and the magnetron sputtering target is started to perform the magnetron sputtering operation.

[0072] The foregoing description illustrates and describes preferred embodiments of the present invention. As previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. A manufacturing apparatus for a lightweight plunger rod, comprising a cylindrical equipment chamber (1), a frame (11) disposed below the equipment chamber (1), a working cavity (12) disposed inside the equipment chamber (1), an operating door (15) hinged to the front side of the equipment chamber (1), and a control console (2) disposed outside the equipment chamber (1), the control console (2) being signal-controlled connected to the equipment chamber (1), characterized in that, Also includes: The mounting fixture (3) is arranged opposite to each other at both ends of the working cavity (12). The mounting fixture (3) includes an upper fixture (31) and a lower fixture (32). The upper fixture (31) is rotatably mounted on the top of the working cavity (12), and the lower fixture (32) is rotatably mounted on the bottom of the working cavity (12). The bottom of the lower fixture (32) extends out of the equipment chamber (1) and is connected to a rotating component (33). The rotating component (33) includes a transmission gear (331), a rotating gear (332), and a rotating motor (333). The transmission gear (331) is coaxially arranged with the lower fixture (32) and fixed at the bottom of the lower fixture (32). The rotating gear (332) meshes with the transmission gear (331). The rotating gear (332) is also sleeved on the output shaft of the rotating motor (333). The rotating motor (333) is mounted on the frame (11). The workpiece (4) is installed in the working cavity (12). The workpiece (4) includes a cladding workpiece (41) and an impact workpiece (42) arranged opposite to each other. Vertical cladding tracks (13) and impact tracks (14) are respectively provided in the working cavity (12) corresponding to the cladding workpiece (41) and the impact workpiece (42). The cladding tracks (13) and impact tracks (14) are both arranged along the axis of the working cavity (12) and fixed to the inner side wall of the equipment room (1). The cladding workpiece (41) includes a cladding drive, a cladding component (412) and a cladding cable (413). The cladding drive controls the cladding. The component (412) is slidably set on the cladding track (13). One end of the cladding cable (413) is connected to the cladding component (412) and slides vertically with the cladding component (412). The other end extends out of the equipment chamber (1). The impact workpiece (42) includes an impact drive, an impact component (422) and a power line (423). The impact drive controls the impact component (422) to slide on the impact track (14). One end of the power line (423) is connected to the impact component (422) and slides vertically with the impact component (422). The other end extends out of the equipment chamber (1). An impact power supply is provided outside the equipment chamber (1) and connected to the power line (423). A magnetically controlled workpiece (5) is disposed in a working cavity (12). The magnetically controlled workpiece (5) includes an operating target (51) and an isolation component (52). Multiple operating targets (51) are disposed in a circumferential array on the inner side wall of the equipment chamber (1). The isolation component (52) is disposed in the working cavity (12) near the top. The isolation component (52) includes two oppositely disposed movable isolations (521) and two oppositely disposed fixed isolations (522). The movable isolations (521) are disposed on the top of the cladding workpiece (41) and the impact workpiece (42). The fixed isolations (522) are arc-shaped and oppositely disposed in the working cavity (12). The cladding component (412) includes a cladding operating arm (4121), a cladding head (4122), and a cladding slider (4123). The cladding operating arm (4121) is a telescopic structure and is arranged radially along the equipment chamber (1). The cladding head (4122) is fixed at one end of the cladding operating arm (4121) near the center of the equipment chamber (1), and the cladding slider (4123) is fixed at the other end of the cladding operating arm (4121). The cladding slider (4123) is slidably positioned within the cladding track (13) by a cladding drive control. The cladding cable (413) includes a powder feeding channel (4131) and a cladding component power cable (4123). The cladding cable (4132) and optical fiber (4133) extend out of the equipment room (1) through the cladding slider (4123) along the cladding track (13). An operating device (6) is also provided outside the equipment room (1) and connected to the cladding cable (413). The operating device (6) includes a powder feeder (61), a cladding power supply (62), and a laser emitter (63). The other end of the powder feeding channel (4131) is connected to the powder feeder (61), the other end of the cladding power line (4132) is connected to the cladding power supply (62), and the other end of the optical fiber (4133) is connected to the laser emitter (63). The impact component (422) includes an impact operating arm (4221), an impact head (4222), and an impact slider (4223). The impact operating arm (4221) is a telescopic structure and is arranged radially along the equipment chamber (1). The impact head (4222) is fixed at one end of the impact operating arm (4221) near the center of the equipment chamber (1), and the impact slider (4223) is fixed at the other end of the impact operating arm (4221). A cladding layer is formed on the surface of the plunger rod by laser alloying with alloy powder. During the laser cladding process, residual stress in the cladding layer is continuously strengthened and eliminated by ultrasonic impact, which enhances the surface hardness of the plunger rod after laser cladding. Finally, a magnetron sputtering film is deposited on the cladding layer to further improve the surface hardness of the plunger rod, thus completing the manufacturing of the plunger rod.

2. The manufacturing equipment for a lightweight plunger rod according to claim 1, characterized in that, The upper clamp (31) includes an upper jaw disc (311), three upper jaw bodies (312), and an upper jaw drive (313). The upper jaw drive (313) is located inside the upper jaw disc (311) and controls the three upper jaw bodies (312) to move radially relative to each other along the upper jaw disc (311). The lower clamp (32) includes a lower jaw disc (321), three lower jaw bodies (322), and a lower jaw drive (323). The lower jaw drive (323) is located inside the lower jaw disc (321) and controls the three lower jaw bodies (322) to move radially relative to each other along the lower jaw disc (321). A rolling bearing (3211) is also fitted on the lower outer wall near the bottom of the lower jaw disc (321). The rolling bearing (3211) is keyed to the lower jaw disc (321) and is rotatably mounted at the bottom of the equipment room (1).

3. The manufacturing equipment for a lightweight plunger rod according to claim 1, characterized in that, The equipment room (1) has a through hole (16) corresponding to the cladding cable (413). A sealing element (17) is provided at the through hole (16). The sealing element (17) includes a sealing ring (171) and an expansion ring (172). The sealing ring (171) is snapped into the through hole (16). The expansion ring (172) extends onto the sealing ring (171) and has a through hole (1721) in the middle. The expansion ring (172) is located on the side of the sealing ring (171) away from the equipment room (1). The top of the cladding track (13) has two vertically parallel conductors corresponding to the cladding cable (413). The guide wheel (131) is positioned and rotatably installed in the equipment room (1) with its axis set along the width direction of the cladding track (13). The cladding slider (4123) is also positioned and rotatably installed on the side near the cladding track (13). The axis of the guide wheel (132) is also set along the width direction of the cladding track (13). There are shielding plates (133) arranged opposite each other in the cladding track (13). The shielding plates (133) are set along the length direction of the cladding track (13) and their width is less than half the width of the cladding track (13). There is a gap between the two shielding plates (133).

4. The manufacturing equipment for a lightweight plunger rod according to claim 3, characterized in that, An adjustment component (7) is also provided between the operating device (6) and the equipment room (1). The cladding cable (413) is wound around the adjustment component (7). The adjustment component (7) includes an adjustment frame (71), an adjustment drive (72), multiple guide wheels (73) and sliding wheels (74). The guide wheels (73) and sliding wheels (74) are all rotatably mounted on the adjustment frame (71). The guide wheels (73) are arranged in pairs and are located on both sides of the sliding wheels (74). The sliding wheels (74) are also controlled by the adjustment drive (72) to be raised and lowered on the adjustment frame (71). The adjustment frame (71) is provided with a sliding groove (711) for the sliding wheels (74) to slide.

5. The manufacturing equipment for a lightweight plunger rod according to claim 1, characterized in that, The equipment room (1) is also provided with a through hole (16) corresponding to the power line (423). A sealing element (17) is provided at the through hole (16). Limiting pieces (141) are provided opposite to each other in the impact rail (14). The limiting pieces (141) are arranged along the length of the impact rail (14) and their width is less than half the width of the impact rail (14). A gap is left between the two limiting pieces (141).

6. The manufacturing equipment for a lightweight plunger rod according to claim 1, characterized in that, The two movable isolations (521) are connected by a telescopic drive with double-ended output shafts. Each movable isolation (521) includes two oppositely arranged isolation plates (5211) and an isolation drive (5212). The isolation drive (5212) controls the relative movement of the two isolation plates (5211). The isolation plates (5211) are rotatably mounted above the fixed isolation (522). The isolation plates (5211) have clearance notches (52111) corresponding to the cladding track (13) and the impact track (14). Each fixed isolation (522) also extends two limiting clips (5221), which are oppositely arranged on both sides of the fixed isolation (522).

7. The manufacturing equipment for a lightweight plunger rod according to claim 6, characterized in that, Each of the isolation drives (5212) includes two drive gears (52121) and a drive rack (52122). The drive rack (52122) is meshed with the two drive gears (52121) on both sides respectively. The drive gears (52121) are mounted on the isolation plate (5211) and drive the isolation plate (5211) to move. The drive rack (52122) is located in the middle of the two isolation plates (5211) and is laterally slidable above the fixed isolation (522). The drive rack (52122) is controlled by a telescopic drive with a double-ended output shaft.

Images