Assembly welding process for exhaust cylinder support with through square hole

Abstract

The invention provides an assembling and welding process for an exhaust cylinder support with a through square hole, which comprises the following steps of: 1, decomposing the process of the exhaust cylinder support, 2, blanking and processing four parts, 3, manufacturing a welding tool, 4, assembling and welding an upper block body, a second cover plate and a lower block body, 5, secondarily assembling and welding a C-shaped support, 6, assembling and welding a first cover plate, and 7, assembling and welding a second cover plate. By means of the process, exhaust cylinder support welding deformation can be reduced, it is guaranteed that the exhaust cylinder support can meet the size after being welded to the inner barrel and the outer barrel, and all related welding seams smoothly pass MT + UT inspection. The tool design can be popularized to similar products with through square hole supporting assemblies.

Description

Technical Field

[0001] The invention relates to the technical field of exhaust cylinder processing and manufacturing, and mainly relates to an exhaust cylinder support welding process with a through square hole. Background Art

[0002] Take the exhaust cylinder of 9HA.02 BLOCK A as an example, see Figure 1-4 The upper and lower parts of the carbon steel body have four exhaust cylinder supports (1) connected to the inner and outer cylinders, and the exhaust cylinder supports (1) are evenly distributed at 45 degrees. The exhaust cylinder supports (1) are designed to penetrate the square hole (4) with a depth of 1300mm, which penetrates the entire exhaust cylinder support (1). Its cross-sectional shape is as follows: Figure 5 As shown. From the manufacturing process, there are two main options for the exhaust cylinder support (1) welding process: one is that the entire exhaust cylinder support is a part, and the shape and square hole are processed before welding after cutting, and then welded to the inner and outer cylinders; the other is that the entire exhaust cylinder support is a part, and the shape is processed before welding after cutting, and then welded to the inner and outer cylinders, and the square hole is processed after the overall welding.

[0003] Among them, the first solution has the disadvantage that, due to the deep depth of the through square hole (4), there is a certain degree of processing difficulty in the overall processing of the internal hollow structure, the molding difficulty is high, and welding deformation is easily generated later; The second solution has the disadvantage that the through-hole (4) is processed after welding, which is inconvenient to process and usually prone to subsequent welding deformation. Summary of the invention

[0004] In order to solve the above-mentioned technical problems, the present invention provides an exhaust cylinder support welding process with a through square hole. This process decomposes the entire exhaust cylinder support structure, and then welds and assembles the components with the help of assembly positioning tooling, thereby forming an anti-deformation process technology, which solves the manufacturing problem that the depth of the square hole on the exhaust cylinder support exceeds 1 meter. The use of this process ensures the production and assembly of the exhaust cylinder support with a through square hole. During the final welding inspection, special inspectors check the product size and weld quality. The inspection results meet the requirements of the drawing specifications, which provides rational experience for the assembly of the same type of exhaust cylinder supports and other components.

[0005] In order to realize the above technical features, the object of the present invention is achieved as follows: the exhaust cylinder support welding process with a through square hole comprises the following steps: Step 1, process breakdown of exhaust cylinder support: According to the structural characteristics of the exhaust cylinder support, the exhaust cylinder support is divided into four parts, including an upper block, a lower block, a first cover plate and a second cover plate; Step 2, cutting and processing of four parts: According to the size structure of the upper block, the lower block, the first cover plate and the second cover plate after decomposition, the materials are cut respectively, and then the four parts are processed separately; Step 3, production of welding tooling: The welding jig is used to support the upper block, the lower block and the second cover plate during assembly welding, wherein the welding jig includes a bottom plate, and a first support plate and a second support plate arranged in parallel are fixed on the top of the bottom plate; during welding, the upper block, the second cover plate and the lower block are supported on the top of the first support plate and the second support plate; Step 4: Assembly and welding of the upper block, the second cover plate and the lower block: The upper block, the second cover plate and the lower block are supported on the top of the welding fixture, and the three are assembled, and then the tops of the upper block and the lower block are pre-connected by using process support bars; the combined seams of the second cover plate and the upper block and the lower block are welded, and finally a C-shaped support is formed; Step 5, secondary assembly welding of C-type support: When the exhaust cylinder is assembled, weld the C-type support between the inner cylinder and the outer cylinder; Step 6, assembly welding of the first cover plate: After the C-shaped support is assembled and welded, the first cover plate is welded to the opening of the C-shaped support to form a complete exhaust cylinder support.

[0006] In step 1, a lower trough is processed at the bottom end of the upper block, and an upper trough is processed at the top end of the lower block. The first cover plate and the second cover plate are respectively located between the upper block and the lower block and form a through square hole after assembly.

[0007] In the step 2, a first welding groove is formed at a sealing position where the first cover plate is combined with the upper block and the lower block, and a second welding groove is formed at a sealing position where the second cover plate is combined with the upper block and the lower block.

[0008] In step 3, the first support plate and the second support plate adopt the same structure, and the tops of the first support plate and the second support plate are processed with a first bevel, a horizontal edge and a third bevel with different inclinations and respectively used to support the upper block, the second cover plate and the lower block.

[0009] In the process of combining the first cover plate with the upper block and the lower block in step 4, a gap of at least 3 mm is reserved at the root of the second welding groove to ensure the penetration effect; Wherein, the first bevel increases the anti-deformation welding amount by at least 3.5 mm relative to the theoretical contour of the upper block; The horizontal edge increases the anti-deformation welding amount by at least 2mm relative to the theoretical contour of the lower block.

[0010] During assembly in step 4, the upper block and the lower block are respectively pressed against the two ends and the two beveled edges of the first support plate and the second support plate until the gap is less than 0.5 mm. The second cover plate is placed on the horizontal edge, and the gap with the grooves of the upper block and the lower block is evenly adjusted before positioning welding.

[0011] During the welding process in step 4, a full penetration weld is used, a ceramic liner is attached to the back of the second welding groove, GMAW is used for primer, the back of the second welding groove is fully penetrated, the appearance consistency is good, and MT+UT flaw detection is performed after being polished according to the drawing requirements; Then remove the process support bars and check the welding deformation of the C-type support. Since the anti-deformation was done in advance, the deformation caused by welding shrinkage was offset, and no correction was required to meet the requirements of the drawings and secondary assembly.

[0012] The specific welding process of the C-type support in step 5 is as follows: first, draw the assembly line of each component on the platform according to the drawing requirements, which includes the center lines of the 8 C-type supports; The inner cylinder and outer cylinder that have been welded separately are placed on the ground sample. The square holes on the inner cylinder and outer cylinder that match the through square holes have been processed in advance. The square holes on the inner cylinder and outer cylinder are adjusted to match the ground sample line. Install the welded C-shaped support between the inner tube and the outer tube, align the C-shaped hole with the holes on the inner tube and the outer tube respectively, and then perform positioning welding. At this time, do not assemble the first cover plate; After installing 8 C-type supports and the remaining parts in sequence, the exhaust cylinder is welded as a whole. In order to ensure the welding quality of the C-type hole and the inner and outer cylinder welds, the C-type support is welded flat with the inner and outer cylinders toward the outward groove and then the root is carbon planed on the reverse side.

[0013] After the welding of the C-shaped support, the inner tube and the outer tube is completed in step 5, the welds are subjected to MT+UT flaw detection according to the requirements of the drawings, and the first cover plate is assembled after confirming that the welds are qualified.

[0014] In step 6, a semi-enclosed cavity is formed after the first cover plate is assembled, and the root cannot be cleaned from the inside. At this time, a ceramic liner is attached to the back or a protective gas is passed to perform welding, thereby ensuring the welding quality; After completing the welding of the 8 first cover plates in sequence, the weld surface is ground flat, and MT+UT flaw detection is carried out according to the requirements of the drawings. A qualified result means that the assembly and welding work of the exhaust cylinder support with a through square hole is completed.

[0015] The present invention has the following beneficial effects: The present invention develops an anti-deformation process technology by decomposing the exhaust cylinder support process and combining it with assembly positioning tooling, thereby solving the manufacturing problem of the square hole on the exhaust cylinder support exceeding 1 meter in depth. The use of this method ensures the production and assembly of the exhaust cylinder support with a through square hole. During the final welding inspection, special inspectors check the product size and weld quality. The inspection results meet the requirements of the drawing specifications, providing rational experience for the assembly of the same type of exhaust cylinder supports and other components. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0017] Figure 1 This is a diagram of the installation structure of the exhaust cylinder support inside the exhaust cylinder.

[0018] Figure 2 This is the front view of the exhaust cylinder support.

[0019] Figure 3 This is a 3D image from the first perspective of the exhaust cylinder support.

[0020] Figure 4 A 3D image of the exhaust cylinder support from a second perspective.

[0021] Figure 5 for Figure 2 AA view of the center row cylinder supports.

[0022] Figure 6 (a) (b) are exploded views of the exhaust cylinder support.

[0023] Figure 7 (a) (b) are exploded views of the C-type support.

[0024] Figure 8 This is the horizontal placement diagram of the C-type support.

[0025] Fig. 9 This is a three-dimensional diagram of the welding tooling.

[0026] Fig.10 This is the front view of the first support plate of the welding tool.

[0027] Fig.11 It is the support diagram of C-type support on welding fixture.

[0028] Fig.12 This is the layout diagram of the C-type support before welding in step 5.

[0029] Fig.13 This is the welding process diagram of the first cover plate. DETAILED DESCRIPTION

[0030] The embodiments of the present invention are further described below in conjunction with the accompanying drawings.

[0031] See also Figure 6-13 The exhaust cylinder support welding process with a through square hole includes the following steps: Step 1, process breakdown of exhaust cylinder support 1: According to the structural characteristics of the exhaust cylinder support 1, the exhaust cylinder support 1 is divided into four parts, including an upper block 5, a lower block 7, a first cover plate 6 and a second cover plate 8; The bottom end of the upper block 5 is processed with a lower groove, the top end of the lower block 7 is processed with an upper groove, the first cover plate 6 and the second cover plate 8 are respectively located between the upper block 5 and the lower block 7 and form a through square hole 4 after assembly.

[0032] By disassembling the exhaust cylinder support 1, the subsequent processing difficulty of penetrating the square hole 4 is effectively avoided.

[0033] Step 2, cutting and processing of four parts: According to the size structure of the upper block 5, the lower block 7, the first cover plate 6 and the second cover plate 8 after decomposition, the materials are cut respectively, and then the four parts are processed separately; At the same time, a first welding groove 17 is formed at a sealing position where the first cover plate 6 is combined with the upper block 5 and the lower block 7 , and a second welding groove 16 is formed at a sealing position where the second cover plate 8 is combined with the upper block 5 and the lower block 7 .

[0034] Pre-processing to form the corresponding first welding groove 17 and second welding groove 16 facilitates ensuring the subsequent welding quality and reliability.

[0035] Step 3, production of welding tooling: Due to the unique structural form of the exhaust cylinder support 1, if the upper block 5, the lower block 7, the first cover plate 6 and the second cover plate 8 are assembled at one time and then welded to the inner and outer cylinders, there will be many welds whose back sides cannot be cleaned, and the weld penetration cannot be guaranteed, and the weld quality cannot be guaranteed. If there are risks in the welds, it will affect the safety of the unit.

[0036] Based on the above considerations, the assembly and welding process of the exhaust cylinder support 1 is decomposed. During one assembly, only the upper block 5, the lower block 7 and the second cover plate 8 are assembled. That is, the three components are supported and assembled in the part state. Fig. 9 On the welding tool shown; The welding jig is used to support the upper block 5, the lower block 7 and the second cover plate 8 during assembly welding, wherein the welding jig includes a bottom plate 9, and a first support plate 10 and a second support plate 11 arranged in parallel are fixed on the top of the bottom plate 9; during welding, the upper block 5, the second cover plate 8 and the lower block 7 are supported on the top of the first support plate 10 and the second support plate 11; The first support plate 10 and the second support plate 11 adopt the same structure. The tops of the first support plate 10 and the second support plate 11 are processed with a first bevel 12, a horizontal edge 13 and a third bevel 14 with different inclinations and are respectively used to support the upper block 5, the second cover plate 8 and the lower block 7.

[0037] Step 4, assembly and welding of the upper block 5, the second cover plate 8 and the lower block 7: The upper block 5, the second cover plate 8 and the lower block 7 are supported on the top of the welding fixture and assembled, and then the tops of the upper block 5 and the lower block 7 are pre-connected by using the process support ribs 15; the combined seams of the second cover plate 8 and the upper block 5 and the lower block 7 are welded, and finally a C-shaped support is formed; In order to ensure the best penetration effect, during the combined welding of the first cover plate 6 with the upper block 5 and the lower block 7, a gap of at least 3 mm is reserved at the root of the second welding groove 16 to ensure the penetration effect; The first bevel 12 increases the anti-deformation welding amount by 3.5 mm relative to the theoretical profile of the upper block 5; The horizontal edge 13 increases the anti-deformation welding amount by 2 mm relative to the theoretical profile of the lower block 7 .

[0038] During assembly, the upper block 5 and the lower block 7 are respectively pressed against the two ends and the two beveled edges of the first support plate 10 and the second support plate 11 until the gap is less than 0.5 mm. The second cover plate 8 is placed on the horizontal edge 13, and the gap between the upper block 5 and the groove of the lower block 7 is evenly adjusted before positioning welding. During the welding process, a full penetration weld is used, a ceramic liner is attached to the reverse side of the second welding groove 16, GMAW is used for primer, and the reverse side of the second welding groove 16 is fully penetrated, with good appearance consistency. After being polished according to the drawing requirements, MT+UT flaw detection is performed; Then the process support rib 15 is removed to check the welding deformation of the C-type support. As the reverse deformation is done in advance, the deformation caused by welding shrinkage is offset, and no correction is required to meet the requirements of the drawings and secondary assembly.

[0039] Step 5, secondary assembly welding of C-type support: When the exhaust cylinder is assembled, the C-shaped support is welded between the inner cylinder 3 and the outer cylinder 2; The specific assembly and welding process of the C-type support is as follows: First, draw the assembly site sample lines of each component on the platform according to the requirements of the drawing, which includes the center lines of the 8 C-type supports; The inner cylinder 3 and the outer cylinder 2 that have been welded separately are placed on the ground sample. The square holes on the inner cylinder 3 and the outer cylinder 2 that match the through square hole 4 have been processed in advance. The square holes on the inner cylinder 3 and the outer cylinder 2 are adjusted to match the ground sample line. Install the welded C-shaped support between the inner tube 3 and the outer tube 2, align the C-shaped holes with the holes above the inner tube 3 and the outer tube 2, and then perform positioning welding. At this time, do not install the first cover plate 6; After installing 8 C-type supports and the remaining parts in sequence, the exhaust cylinder is welded as a whole. In order to ensure the welding quality of the C-type hole and the inner and outer cylinder welds, the C-type support is welded flat with the inner and outer cylinders toward the outer grooves and then the back side is carbon planed to clean the roots. After the welding of the C-type support, the inner tube 3 and the outer tube 2 is completed, the welds are subjected to MT+UT flaw detection according to the requirements of the drawings. After confirming that the welds are qualified, the first cover plate 6 is assembled.

[0040] Step 6, assembly welding of the first cover plate 6: After the C-shaped support is assembled and welded, the first cover plate 6 is welded to the opening of the C-shaped support to form a complete exhaust cylinder support 1.

[0041] Since the first cover plate 6 forms a semi-enclosed cavity after assembly, it is impossible to clean the root from the inside. In this case, a ceramic liner is attached to the back or a protective gas is used for welding to ensure the welding quality. After the welding of the eight first cover plates 6 is completed in sequence, the weld surface is ground and MT+UT flaw detection is performed according to the requirements of the drawings. If it is qualified, it means that the welding work of the exhaust cylinder support 1 with a through square hole is completed.

Claims

1. The exhaust cylinder support welding process with a through square hole is characterized in that: The following steps are involved: Step 1, process breakdown of exhaust cylinder support (1): According to the structural characteristics of the exhaust cylinder support (1), the exhaust cylinder support (1) is divided into four parts, including an upper block (5), a lower block (7), a first cover plate (6) and a second cover plate (8); Step 2, cutting and processing of four parts: According to the size and structure of the upper block (5), the lower block (7), the first cover plate (6) and the second cover plate (8) after decomposition, the materials are cut respectively, and then the four parts are processed separately; Step 3, production of welding tooling: The welding tool is used to support the upper block (5), the lower block (7) and the second cover plate (8) during assembly welding, wherein the welding tool comprises a bottom plate (9), and a first support plate (10) and a second support plate (11) arranged in parallel are fixed on the top of the bottom plate (9); during welding, the upper block (5), the second cover plate (8) and the lower block (7) are supported on the top of the first support plate (10) and the second support plate (11); Step 4: Assembling and welding the upper block (5), the second cover plate (8) and the lower block (7): The upper block (5), the second cover plate (8) and the lower block (7) are supported on the top of the welding fixture and assembled, and then the tops of the upper block (5) and the lower block (7) are pre-connected using process support bars (15); the combined seams of the second cover plate (8) and the upper block (5) and the lower block (7) are welded, and finally a C-shaped support is formed; Step 5, secondary assembly welding of C-type support: When the exhaust cylinder is assembled, the C-shaped support is welded between the inner cylinder (3) and the outer cylinder (2); Step 6, assembly welding of the first cover plate (6): After the C-shaped support is welded, the first cover plate (6) is welded to the opening of the C-shaped support, thereby forming a complete exhaust cylinder support (1).

2. The exhaust cylinder support welding process with through square holes according to claim 1 is characterized in that: In step 1, a lower groove is processed at the bottom end of the upper block (5), and an upper groove is processed at the top end of the lower block (7). The first cover plate (6) and the second cover plate (8) are respectively located between the upper block (5) and the lower block (7) and form a through square hole (4) after assembly.

3. The exhaust cylinder support welding process with through square holes according to claim 2 is characterized in that: In step 2, a first welding groove (17) is formed by processing at the sealing portion where the first cover plate (6) is combined with the upper block (5) and the lower block (7), and a second welding groove (16) is formed by processing at the sealing portion where the second cover plate (8) is combined with the upper block (5) and the lower block (7).

4. The exhaust cylinder support welding process with through-hole according to claim 3 is characterized in that: In step 3, the first support plate (10) and the second support plate (11) have the same structure, and the tops of the first support plate (10) and the second support plate (11) are processed with a first bevel (12), a horizontal edge (13) and a third bevel (14) having different inclinations and respectively used to support the upper block (5), the second cover plate (8) and the lower block (7).

5. The exhaust cylinder support welding process with through square holes according to claim 4 is characterized in that: In the process of combining the first cover plate (6) with the upper block (5) and the lower block (7) in step 4, a gap of at least 3 mm is reserved at the root of the second welding groove (16) to ensure a thorough penetration effect; The first bevel (12) increases the anti-deformation welding amount by at least 3.5 mm relative to the theoretical profile of the upper block (5); The horizontal edge (13) increases the anti-deformation welding amount by at least 2 mm relative to the theoretical contour of the lower block (7).

6. The exhaust cylinder support welding process with through square holes according to claim 5 is characterized in that: During assembly in step 4, the upper block (5) and the lower block (7) are respectively attached to the two ends and the two oblique edges of the first support plate (10) and the second support plate (11) until the gap is less than 0.5 mm, and the second cover plate (8) is placed on the horizontal edge (13), and the gap with the grooves of the upper block (5) and the lower block (7) is evenly aligned and then tack welded.

7. The exhaust cylinder support welding process with through square holes according to claim 6 is characterized in that: During the welding process in step 4, a full penetration weld is used, a ceramic liner is attached to the back of the second welding groove (16), GMAW is used for primer, the back of the second welding groove (16) is fully penetrated, the appearance is consistent, and MT+UT flaw detection is performed after being polished according to the drawing requirements; Then, the process support bar (15) is removed to check the welding deformation of the C-type support. Since the anti-deformation is pre-made to offset the deformation caused by welding shrinkage, no correction is required to meet the requirements of the drawing and secondary assembly.

8. The exhaust cylinder support welding process with through square holes according to claim 7 is characterized in that: The specific welding process of the C-type support in step 5 is as follows: first, draw the assembly line of each component on the platform according to the drawing requirements, which includes the center lines of the 8 C-type supports; The inner cylinder (3) and the outer cylinder (2) which have been separately welded are placed on the ground sample, wherein the square holes on the inner cylinder (3) and the outer cylinder (2) that match the through square hole (4) have been processed in advance, and the square holes on the inner cylinder (3) and the outer cylinder (2) are adjusted to coincide with the ground sample line; The welded C-shaped support is installed between the inner cylinder (3) and the outer cylinder (2), and the C-shaped hole is aligned with the upper holes of the inner cylinder (3) and the outer cylinder (2) respectively, and then tack welded. At this time, the first cover plate (6) is not installed; After installing 8 C-type supports and the remaining parts in sequence, the exhaust cylinder is welded as a whole. In order to ensure the welding quality of the C-type hole and the inner and outer cylinder welds, the C-type support is welded flat with the inner and outer cylinders toward the outward groove and then the root is carbon planed on the reverse side.

9. The exhaust cylinder support welding process with through-hole according to claim 7 is characterized in that: After the welding of the C-shaped support, the inner tube (3) and the outer tube (2) is completed in step 5, the welds are subjected to MT+UT flaw detection according to the requirements of the drawings, and the first cover plate (6) is assembled after confirming that the welds are qualified.

10. The exhaust cylinder support welding process with through square holes according to claim 7, characterized in that: In step 6, a semi-enclosed cavity is formed after the first cover plate (6) is assembled, and the root cannot be cleaned from the inside. In this case, welding is performed by attaching a ceramic liner to the back or passing a protective gas, thereby ensuring the welding quality; After the welding of the eight first cover plates (6) is completed in sequence, the weld surface is ground flat and MT+UT flaw detection is performed according to the requirements of the drawing. If the test is qualified, it means that the welding work of the exhaust cylinder support (1) with a through square hole is completed.

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