Mining electric shovel bucket structure and mining electric shovel bucket processing method

Abstract

The present invention provides a mining electric shovel bucket structure and a mining electric shovel bucket processing method, the structure comprising: an upper box structure, a side wall structure and a lower box structure; the mining electric shovel bucket structure has a length direction, a height direction and a width direction that are perpendicular to each other; wherein, the upper box structure comprises an upper plate body, a lower plate body, a plurality of transverse reinforcing ribs and a plurality of longitudinal reinforcing ribs; the extension direction of the transverse reinforcing ribs is parallel to the width direction, and the two ends of the transverse reinforcing ribs along the height direction are fixedly connected to the upper plate body and the lower plate body respectively; the present invention forms a grid-like support structure distributed transversely along the width direction and longitudinally along the length direction inside the upper box body, thereby improving the overall load-bearing capacity and durability of the mining electric shovel bucket structure, improving the stability and safety of the electric shovel under long-term work, solving the common mechanical design defects of the existing upper box body, and ensuring the excavation work efficiency of the electric shovel equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of mining equipment, and in particular to a mining electric shovel bucket structure and a mining electric shovel bucket processing method. Background Art

[0002] The single bucket capacity of the mining shovel used in large open-pit mines is generally 35m 3 , even 55m 3 The weight of this type of large electric shovel equipment can reach 1200 to 1500 tons or more, such as 55m 3 The shovel has a maximum unloading height of 10 meters, a maximum pushing force of 112 tons, a maximum lifting force of 290 tons, and a theoretical productivity of 6,600 cubic meters per hour. The shovel bucket is the primary excavation device of the shovel. It typically consists of a bucket body, bail, bottom, and lip. The bucket body, the main body of the shovel bucket, comprises a lower wall for carrying excavated material and an upper wall (i.e., the upper box) for connecting to other equipment. It has a wide mouth overall.

[0003] At present, the bucket body failures of existing electric shovel buckets are basically concentrated in the upper box position. The root cause of deformation, cracking and other failures of the upper box is the mechanical design defects of the upper box structure. The structure of the upper box of existing electric shovel buckets is usually a double-layer steel plate structure, that is, the two layers of steel plates are arranged in parallel, and an intermediate rib (for example, an intermediate rib with a length of 2160mm) is provided in the middle of the two layers of steel plates along the left and right directions. It is welded and fixed to the upper and lower layers of steel plates for support. After a certain period of actual operation of the electric shovel bucket, due to the only intermediate rib in the middle of the upper box and no other supporting ribs, when the electric shovel bucket is subjected to an impact force exceeding 100 tons or even higher during the mining process, the shear resistance of the two sides of the upper box is weak and it is very easy to deform. Even if the thickness of the upper and lower layers of steel plates reaches more than 30mm, the upper box structure will inevitably deform, crack and other failures under the huge external force and impact during the mining process, seriously reducing the excavation efficiency of the electric shovel equipment. Summary of the Invention

[0004] The present invention provides a mining electric shovel bucket structure and a mining electric shovel bucket processing method, so as to solve the problem in the prior art that the upper box of the electric shovel bucket has weak shearing resistance and is very prone to deformation, cracking and other faults.

[0005] In order to solve the above problems, according to one aspect of the present invention, a mining electric shovel bucket structure is provided, comprising: an upper box structure, a side wall structure and a lower box structure; the mining electric shovel bucket structure has a length direction, a height direction and a width direction that are perpendicular to each other; the side wall structure is respectively connected to the two ends of the upper box structure along the width direction and the two ends of the lower box structure along the width direction; the upper box structure is located above the lower box structure and is used to connect to an external mechanical arm; a receiving cavity is formed between the side wall structure, the upper box structure and the lower box structure, and the receiving cavity is used to receive the excavated material; wherein the upper box structure includes an upper plate body , a lower plate body, a plurality of transverse reinforcing ribs and a plurality of longitudinal reinforcing ribs; the two ends of the upper plate body along the width direction and the two ends of the lower plate body along the width direction are respectively connected to the side wall structure; the upper plate body is located above the lower plate body, and the two are arranged in parallel and spaced apart; the extension direction of the transverse reinforcing ribs is parallel to the width direction, and the two ends of the transverse reinforcing ribs along the height direction are respectively fixedly connected to the upper plate body and the lower plate body; the extension direction of the longitudinal reinforcing ribs is parallel to the length direction, and the two ends of the longitudinal reinforcing ribs along the height direction are respectively fixedly connected to the upper plate body and the lower plate body; a plurality of transverse reinforcing ribs are arranged in parallel and spaced apart along the length direction, and a plurality of longitudinal reinforcing ribs are arranged in parallel and spaced apart along the width direction.

[0006] Furthermore, both ends of the transverse reinforcing ribs along the width direction are fixedly connected to the side wall structure respectively; and one end or both ends of the longitudinal reinforcing ribs along the length direction are fixedly connected to the transverse reinforcing ribs.

[0007] Furthermore, multiple transverse reinforcing ribs are projected along the length direction, and the projections of the multiple reinforcing ribs overlap; and / or, multiple longitudinal reinforcing ribs are divided into multiple groups, and multiple longitudinal reinforcing ribs in each group are projected along the length direction, and the projections of multiple longitudinal reinforcing ribs in the same group overlap.

[0008] Furthermore, there is at least one through hole on the transverse reinforcement ribs and the longitudinal reinforcement ribs to reduce weight; the two ends of the upper plate body along the width direction and the two ends of the lower plate body along the width direction are fixedly connected to the side wall structure by welding; the two ends of the transverse reinforcement ribs along the height direction are fixedly connected to the upper plate body and the lower plate body by welding; the two ends of the longitudinal reinforcement ribs along the height direction are fixedly connected to the upper plate body and the lower plate body by welding.

[0009] Furthermore, the through hole is a waist-shaped hole, and the through hole on the transverse reinforcement rib is the same size as the through hole on the longitudinal reinforcement rib; there are two through holes on the transverse reinforcement rib, and the two through holes are symmetrically arranged with respect to the first vertical plane, and the distance between the centroid positions of the two through holes is not less than half of the size of the transverse reinforcement rib in the width direction, and the two ends of the transverse reinforcement rib along the width direction are symmetrically arranged with respect to the first vertical plane; there is one through hole on the longitudinal reinforcement rib, and the through hole is symmetrically arranged with respect to the second vertical plane, and the two ends of the longitudinal reinforcement rib along the length direction are symmetrically arranged with respect to the second vertical plane.

[0010] Furthermore, at least one of the transverse reinforcing ribs, longitudinal reinforcing ribs, upper plate body and lower plate body is made of at least one of the alloy materials with grades Q345A, Mn13, Mn14, Mn13Cr2, and ZGMn13; the distance between two adjacent longitudinal reinforcing ribs is not greater than 600 mm; the distance between two adjacent transverse reinforcing ribs is not greater than 900 mm; and the thickness of the upper plate body and the lower plate body is not less than 16 mm.

[0011] According to another aspect of the present invention, a method for processing a mining electric shovel bucket is provided, which is used to process the above-mentioned mining electric shovel bucket structure. The method for processing the mining electric shovel bucket comprises the following steps: S1, performing root cleaning and grinding treatment on the positions where the upper box structure, the side wall structure and the lower box structure need to be welded; then welding the side wall structure to the lower box structure at both ends in the width direction; S2, welding the lower plate body to the side wall structure at both ends in the width direction, and then welding a plurality of transverse reinforcing ribs to the lower plate body in sequence; when welding each transverse reinforcing rib, welding is performed simultaneously from both ends of the transverse reinforcing rib in the width direction, and the extension direction of the weld is controlled to be parallel to the width direction; S3, welding a plurality of longitudinal reinforcing ribs to the lower plate body in sequence, and welding one or both ends of each longitudinal reinforcing rib in the length direction to the adjacent transverse reinforcing rib; S4, welding the upper plate body to the side wall structure at both ends in the width direction, and then welding a plurality of transverse reinforcing ribs and a plurality of longitudinal reinforcing ribs to the upper plate body in sequence.

[0012] Furthermore, in at least one of step S1, step S2, step S3 and step S4, insulation treatment is performed after welding is completed, and the temperature range of the weld position is controlled to be 150°C to 200°C, and the insulation time is within the range of 2 to 2.5 hours.

[0013] Furthermore, in at least one of step S1, step S2, step S3 and step S4, the welding position to be welded must be preheated during welding, and the preheating temperature range is 120°C ± 5°C. During welding, the interlayer temperature is controlled to be no more than 200°C to ensure the quality of the weld; and / or, in at least one of step S1, step S2, step S3 and step S4, the welding method is carbon dioxide gas shielded welding, the solder is low-carbon flux-cored wire, and the weld position is ultrasonically inspected after welding, and the defective position is polished and cleaned with an angle grinder before being repaired by welding.

[0014] Furthermore, in at least one of step S1, step S2, step S3 and step S4, a base laying step, a filling step and a covering step are sequentially performed for each welding; in the base laying step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 26-27 V, the current is in the range of 180-210 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.2-0.25 m / min; in the filling step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 27-29 V, the current is in the range of 210-250 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.25-0.3 m / min; in the covering step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 27-28 V, the current is in the range of 180-210 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.2-0.25 m / min.

[0015] Applying the technical solution of the present invention, the present invention provides a mining electric shovel bucket structure, comprising: an upper box structure, a side wall structure and a lower box structure; the mining electric shovel bucket structure has a length direction, a height direction and a width direction that are perpendicular to each other; the side wall structure is respectively connected to the two ends of the upper box structure along the width direction and the two ends of the lower box structure along the width direction; the upper box structure is located above the lower box structure and is used to connect to an external mechanical arm; a receiving cavity is formed between the side wall structure, the upper box structure and the lower box structure, and the receiving cavity is used to receive the excavated material; wherein the upper box structure comprises an upper plate body, a lower plate body, and a lower plate body. body, multiple transverse reinforcing ribs and multiple longitudinal reinforcing ribs; the two ends of the upper plate body along the width direction and the two ends of the lower plate body along the width direction are respectively connected to the side wall structure; the upper plate body is located above the lower plate body, and the two are arranged in parallel and spaced apart; the extension direction of the transverse reinforcing ribs is parallel to the width direction, and the two ends of the transverse reinforcing ribs along the height direction are fixedly connected to the upper plate body and the lower plate body respectively; the extension direction of the longitudinal reinforcing ribs is parallel to the length direction, and the two ends of the longitudinal reinforcing ribs along the height direction are fixedly connected to the upper plate body and the lower plate body respectively; multiple transverse reinforcing ribs are arranged in parallel and spaced apart along the length direction, and multiple longitudinal reinforcing ribs are arranged in parallel and spaced apart along the width direction.

[0016] The present invention provides an upper box structure including an upper plate, a lower plate, multiple transverse reinforcing ribs and multiple longitudinal reinforcing ribs, so that a grid-like support structure distributed transversely along the width direction and longitudinally along the length direction is formed inside the upper box structure, that is, the cooperative support between the multiple transverse reinforcing ribs and the multiple longitudinal reinforcing ribs significantly improves the overall shear force resistance of the upper box structure, thereby improving the overall load-bearing capacity and durability of the mining electric shovel bucket structure, reducing the probability of maintenance, improving the stability and safety of the electric shovel under long-term work, avoiding the occurrence of safety hazards, and achieving obvious economic and safety benefits in actual use; the present invention solves the common mechanical design defects of the existing upper box by innovative mechanical structure design of the upper box structure, avoids deformation, cracking and other failures of the upper box structure, and thereby ensures the excavation efficiency of the electric shovel equipment; the present invention has a simple structure and low cost, is easy to assemble and form by welding and perform subsequent maintenance, and is suitable for large-scale promotion and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0018] Figure 1 A partial structural perspective view of an upper box structure provided by an embodiment of the present invention is shown;

[0019] Figure 2 A schematic diagram of a portion of the structure of a transverse reinforcing rib provided by an embodiment of the present invention when viewed from the front is shown;

[0020] Figure 3 A schematic diagram of a portion of the structure of a longitudinal reinforcement rib provided by an embodiment of the present invention is shown in a front view;

[0021] Figure 4 A schematic diagram of the external structure of a mining electric shovel bucket structure provided by an embodiment of the present invention is shown.

[0022] The above drawings include the following reference numerals:

[0023] 10. Upper box structure; 11. Upper plate; 12. Lower plate; 13. Horizontal reinforcement ribs; 14. Longitudinal reinforcement ribs;

[0024] 20. Side wall structure;

[0025] 30. Lower box structure;

[0026] 40. Accommodation cavity;

[0027] 50. Through hole. DETAILED DESCRIPTION

[0028] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0029] like Figures 1 to 4 As shown, an embodiment of the present invention provides a mining electric shovel bucket structure, comprising: an upper box structure 10, a side wall structure 20 and a lower box structure 30; the mining electric shovel bucket structure has a length direction, a height direction and a width direction that are perpendicular to each other; the side wall structure 20 is connected to both ends of the upper box structure 10 along the width direction and the two ends of the lower box structure 30 along the width direction respectively; the upper box structure 10 is located above the lower box structure 30 and is used to connect to an external manipulator; a receiving cavity 40 is formed between the side wall structure 20, the upper box structure 10 and the lower box structure 30, and the receiving cavity 40 is used to receive the excavated material; wherein the upper box structure 10 comprises an upper plate body 11, a lower plate body 12, a plurality of The upper plate 11 and the lower plate 12 are provided with a plurality of transverse reinforcing ribs 13 and a plurality of longitudinal reinforcing ribs 14; the two ends of the upper plate 11 along the width direction and the two ends of the lower plate 12 along the width direction are respectively connected to the side wall structure 20; the upper plate 11 is located above the lower plate 12, and the two are arranged in parallel and spaced apart; the extension direction of the transverse reinforcing ribs 13 is parallel to the width direction, and the two ends of the transverse reinforcing ribs 13 along the height direction are fixedly connected to the upper plate 11 and the lower plate 12 respectively; the extension direction of the longitudinal reinforcing ribs 14 is parallel to the length direction, and the two ends of the longitudinal reinforcing ribs 14 along the height direction are fixedly connected to the upper plate 11 and the lower plate 12 respectively; a plurality of transverse reinforcing ribs 13 are arranged in parallel and spaced apart along the length direction, and a plurality of longitudinal reinforcing ribs 14 are arranged in parallel and spaced apart along the width direction.

[0030] By arranging the upper box structure 10 including the upper plate body 11, the lower plate body 12, the plurality of transverse reinforcing ribs 13 and the plurality of longitudinal reinforcing ribs 14, a grid-like support structure distributed transversely along the width direction and longitudinally along the length direction is formed inside the upper box structure 10, that is, the cooperation support between the plurality of transverse reinforcing ribs 13 and the plurality of longitudinal reinforcing ribs 14 significantly improves the overall shear force resistance of the upper box structure 10, thereby improving the overall load-bearing capacity and durability of the mining electric shovel bucket structure, reducing the probability of maintenance, improving the stability and safety of the electric shovel under long-term operation, avoiding the occurrence of safety hazards, and achieving obvious economic efficiency and safety benefits in actual use; the present invention solves the common mechanical design defects of the existing upper box by innovatively designing the mechanical structure of the upper box structure 10, avoids deformation, cracking and other failures of the upper box structure 10, and thereby ensures the excavation efficiency of the electric shovel equipment; the present invention has a simple structure and low cost, is easy to assemble and form by welding and to carry out subsequent maintenance, and is suitable for large-scale promotion and use.

[0031] like Figures 1 to 4 As shown, both ends of the transverse reinforcing rib 13 along the width direction are fixedly connected to the side wall structure 20 respectively; one end or both ends of the longitudinal reinforcing rib 14 along the length direction are fixedly connected to the transverse reinforcing rib 13.

[0032] By securely connecting the transverse reinforcement ribs 13 to the sidewall structure 20, and by connecting the longitudinal reinforcement ribs 14 to the transverse reinforcement ribs 13, the rigidity of the entire box structure is further enhanced, particularly in the width and length directions. This reinforcement method effectively improves the overall stability of the structure, ensuring that the bucket maintains its shape and performance under high loads. It also reduces stress concentration and avoids cracks and fractures caused by excessive localized stress.

[0033] like Figure 1 As shown, multiple transverse reinforcing ribs 13 are projected along the length direction, and the projections of the multiple reinforcing ribs overlap; and / or, multiple longitudinal reinforcing ribs 14 are divided into multiple groups, and the multiple longitudinal reinforcing ribs 14 in each group are projected along the length direction, and the projections of the multiple longitudinal reinforcing ribs 14 in the same group overlap.

[0034] The projections of the transverse reinforcement ribs 13 are overlapped, and the longitudinal reinforcement ribs 14 are divided into multiple groups and the projections within the same group are overlapped. This arrangement optimizes the layout of the reinforcement ribs in space, achieves the symmetry of the structure and the balance of the planar strength, helps to improve the torsional resistance and bending strength of the bucket structure, makes the structure more stable when subjected to non-uniform loads, reduces structural failures caused by off-center loads, and simplifies the design and manufacturing process.

[0035] like Figure 1As shown, there is at least one through hole 50 on the transverse reinforcement ribs 13 and the longitudinal reinforcement ribs 14 to reduce weight; the two ends of the upper plate body 11 along the width direction and the two ends of the lower plate body 12 along the width direction are fixedly connected to the side wall structure 20 by welding; the two ends of the transverse reinforcement rib 13 along the height direction are fixedly connected to the upper plate body 11 and the lower plate body 12 by welding; the two ends of the longitudinal reinforcement rib 14 along the height direction are fixedly connected to the upper plate body 11 and the lower plate body 12 by welding.

[0036] Through-holes 50 are provided in the transverse and longitudinal ribs 13 and 14, effectively reducing the bucket's overall weight while maintaining structural strength, improving the equipment's energy efficiency and maneuverability. The selected welding method ensures the secure and efficient connection of all components, reduces welding defects, and enhances structural integrity. Precise control of welding parameters further improves weld quality and extends the bucket's lifespan.

[0037] like Figure 2 As shown, the through hole 50 is a waist-shaped hole, and the through hole 50 on the transverse reinforcement rib 13 and the through hole 50 on the longitudinal reinforcement rib 14 are of the same size; the transverse reinforcement rib 13 has two through holes 50, and the two through holes 50 are symmetrically arranged relative to the first vertical plane, and the distance between the centroid positions of the two through holes 50 is not less than half of the dimension of the transverse reinforcement rib 13 in the width direction, and the two ends of the transverse reinforcement rib 13 along the width direction are symmetrically arranged relative to the first vertical plane; the longitudinal reinforcement rib 14 has one through hole 50, and the through hole 50 is symmetrically arranged relative to the second vertical plane, and the two ends of the longitudinal reinforcement rib 14 along the length direction are symmetrically arranged relative to the second vertical plane.

[0038] The design of the waist-shaped hole as the through hole 50 not only reduces material usage and lowers costs, but also maintains the balance and strength of the structure through its symmetrical layout and size control. This hole design optimizes weight without affecting shear resistance, improves the energy efficiency of the equipment, and the symmetrical setting helps to evenly load the structure, avoid stress concentration, and improve the reliability of the bucket under complex working conditions.

[0039] like Figure 1 As shown, at least one of the transverse reinforcing ribs 13, the longitudinal reinforcing ribs 14, the upper plate body 11 and the lower plate body 12 is made of at least one of the alloy materials with grades Q345A, Mn13, Mn14, Mn13Cr2, and ZGMn13; the distance between two adjacent longitudinal reinforcing ribs 14 is not greater than 600 mm; the distance between two adjacent transverse reinforcing ribs 13 is not greater than 900 mm; the thickness of the upper plate body 11 and the lower plate body 12 are not less than 16 mm.

[0040] The use of high-strength alloys such as Q345A and Mn13 for the ribs and plates not only improves wear resistance and weldability, but also ensures structural durability and stability. By limiting the spacing between the longitudinal ribs 14 and the transverse ribs 13, and specifying the minimum thickness of the upper and lower plates, the structural stiffness-to-weight ratio is optimized, allowing the bucket to maintain good structural integrity even under high impact forces, reducing failures due to material fatigue and improving operational safety and efficiency.

[0041] The present invention also provides a mining electric shovel bucket processing method, which is used to process the above-mentioned mining electric shovel bucket structure, and the processing method includes the following steps: S1, performing root cleaning and grinding treatment on the positions where the upper box structure 10, the side wall structure 20 and the lower box structure 30 need to be welded; then welding and fixing the side wall structure 20 and the lower box structure 30 at both ends in the width direction; S2, respectively welding and fixing the two ends of the lower plate body 12 in the width direction to the side wall structure 20, and then sequentially welding and fixing a plurality of transverse reinforcing ribs 13 to the lower plate body 12; When welding each transverse reinforcement rib 13, welding is performed simultaneously from both ends of the transverse reinforcement rib 13 in the width direction, and the extension direction of the weld is controlled to be parallel to the width direction; S3, multiple longitudinal reinforcement ribs 14 are welded and fixed to the lower plate body 12 in turn, and one end or both ends of each longitudinal reinforcement rib 14 along the length direction are welded and fixed to the adjacent transverse reinforcement rib 13; S4, the two ends of the upper plate body 11 along the width direction are welded and fixed to the side wall structure 20, and then multiple transverse reinforcement ribs 13 and multiple longitudinal reinforcement ribs 14 are welded and fixed to the upper plate body 11 in turn.

[0042] This processing method ensures welding quality, reduces welding stress and deformation, and improves structural stability and reliability through steps such as root cleaning and grinding, multi-step welding, and precise control of the welding sequence. The gradual welding of the side wall structure 20, the lower plate 12, and the reinforcement ribs forms a stable frame, ensuring the geometric accuracy of the bucket during the assembly process, thereby improving the overall performance and reducing the frequency and cost of subsequent maintenance.

[0043] Specifically, in at least one of step S1, step S2, step S3 and step S4, insulation treatment is performed after welding is completed, and the temperature range of the weld position is controlled to be 150°C to 200°C, and the insulation time is within the range of 2 to 2.5 hours.

[0044] Post-weld insulation treatment helps eliminate welding residual stress, improves the microstructure of the weld joint, and enhances the overall performance of the weld, including strength, toughness, and crack resistance, thereby extending the service life of the bucket and reducing the risk of structural failure due to welding defects. By controlling the temperature range and insulation time at the weld location, weld collapse and grain coarsening are avoided, ensuring the long-term stability and safety of the welded parts.

[0045] Specifically, in at least one of step S1, step S2, step S3, and step S4, the welding position is preheated during welding, and the preheating temperature range is 120°C ± 5°C. During welding, the interlayer temperature is controlled to be no greater than 200°C to ensure the quality of the weld; and / or, in at least one of step S1, step S2, step S3, and step S4, the welding method is carbon dioxide gas shielded welding, the solder is low-carbon flux-cored wire, and after welding, the weld position is subjected to ultrasonic flaw detection. Defective positions are cleaned and polished with an angle grinder before repair welding;

[0046] Preheating and interlayer temperature control effectively reduce the risk of welding cracks, improve welding quality, and extend the service life of the bucket; the use of carbon dioxide gas shielded welding and low-carbon flux-cored wire, combined with ultrasonic flaw detection, ensures the integrity and reliability of the weld joint, reduces the need for subsequent maintenance and repair, and enhances the structure's fatigue resistance and work safety.

[0047] Specifically, in at least one of step S1, step S2, step S3 and step S4, a base laying step, a filling step and a covering step are sequentially performed each time welding; in the base laying step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 26-27 V, the current is in the range of 180-210 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.2-0.25 m / min; in the filling step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 27-29 V, the current is in the range of 210-250 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.25-0.3 m / min; in the covering step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 27-28 V, the current is in the range of 180-210 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.2-0.25 m / min.

[0048] Through multi-layer and multi-pass welding processes, as well as precise control of welding parameters such as wire diameter, voltage, and current, high-quality welding results are achieved, welding defects are reduced, and structural stability and impact resistance are ensured. This welding process not only improves welding efficiency, but also reduces stress accumulation during the welding process, avoids structural deformation, extends the service life of the bucket, and improves the safety and economy of operations.

[0049] It should be noted that in this solution, the thickness of the transverse reinforcement ribs 13, the longitudinal reinforcement ribs 14, the upper plate body 11 and the lower plate body 12 can all be 30 mm; of course, different or same thickness materials can also be used according to actual use requirements; for example: if the external impact force is slightly smaller, 20 mm thick or even 16 mm thick materials can be used. If the impact force of the mining environment in which the equipment is located is large, materials with a thickness greater than 30 mm can also be used; the material can be Q345A, or existing high manganese wear-resistant steel plate materials such as Mn13, Mn14, Mn13Cr2, ZGMn13, etc. can be used to achieve a balance between wear resistance and weldability.

[0050] The installation of the upper box structure 10 significantly enhances its strength and stability, effectively dissipates stress concentration, and improves its overall impact resistance and wear resistance. The welding process and thermal insulation treatment effectively control welding deformation, reduce welding residual stress, and ensure weld quality and structural reliability. Furthermore, precise material selection and hole design further optimize structural performance, reduce material costs, extend equipment life, and improve the operating efficiency and safety of large electric shovels in harsh working conditions, resulting in significant economic benefits and application value.

[0051] In addition, in the actual research summary, it was found that the upper box structure 10 of the existing electric shovel bucket usually has the following defects during welding: 1. There are defects in welding quality; if a small crack in the bucket body is not dealt with in time or the welding quality is poor, the crack will expand and even the relevant parts will be completely opened or broken. More welding maintenance is carried out at the mining production site. Insufficient welding process conditions will result in low welding quality and the weld will crack again or even multiple times. Such repeated welding maintenance causes the weld and the surrounding materials to begin to harden, and the weldability of the parent material gradually decreases, and the strength life of the weld is greatly shortened. Repeated welding causes the metal grains in the bucket welding part and the surrounding area to coarsen, the structure to harden, and the plastic toughness to drop sharply. The comprehensive mechanical properties cannot meet the requirements of the bucket mining work; 2. There are defects in the bucket box structure; the upper box structure 10 of the original bucket body, after cutting the top during maintenance, it can be clearly found that the rib plate set in the box has weak resistance to deformation and cracking, which is also the main reason for the frequent welding maintenance of the bucket.

[0052] To solve the problems summarized and discovered in the research above, in a specific embodiment of the present invention, the transverse reinforcement ribs 13 and the longitudinal reinforcement ribs 14 are both made of Q345A plate. The specific welding operation is implemented as follows:

[0053] 1. Welding operation steps: Each place that needs to be welded must be cleaned and polished first; the joint form is a T-shaped joint, and the weld form is a butt weld. The welding order is: a. Weld the inner side of the lower plate 12 of the box body; b. Arrange and weld the transverse reinforcement ribs 13 according to the size and position of the designed grid structure on the bottom plate; c. Arrange and weld the longitudinal reinforcement ribs 14 according to the size and position; d. After completing the above welding operations, flip the bucket 90° to form a position with the bucket teeth facing upwards, and weld the outer side of the lower plate 12 of the box body; e. Weld the corner guard at the back of the box body, that is, weld the corner guard to the upper box body at the bottom of the bucket to further strengthen the upper box body structure;

[0054] 2. Multi-layer, multi-pass, two-person counter-welding operation, especially the welding of the transverse reinforcement 13; the total weld length of each transverse reinforcement 13 reaches 2.16 meters. The two-person counter-welding synchronous welding can make the stress of the transverse reinforcement 13 even during the welding process, reduce welding deformation, and ensure the quality of the welding; (Attention must be paid to personnel protection measures during the operation to ensure safe construction);

[0055] 3. Preheating and temperature control: The preheating temperature of the welding part is controlled at 120℃±5℃; during welding, the interlayer temperature should be controlled well and not exceed 200℃ to avoid excessive temperature causing weld collapse, grain coarsening, and affecting weld quality;

[0056] 4. CO2 gas shielded welding was used. Low-carbon flux-cored wire was selected. The welding parameters are detailed in Table 1 below. After welding, the weld was inspected by ultrasonic testing. Defective areas were cleaned with an angle grinder and then repaired by welding. (The welding equipment used was Miller Dimension.TM.812, and the welding wire was Lincoln LW-81Ni1.)

[0057] Table 1 Welding parameters

[0058]

[0059] 5. Insulation after welding: Insulate the vertical welds on both sides and the flat welds of the bottom plate, control the temperature at 150℃~200℃ and the time at 2~2.5 hours.

[0060] The specific calculation process and design principle of an embodiment of the present invention are now described in detail as follows:

[0061] The present invention creatively invents a new structural form for the upper box of the electric shovel bucket; the size of the upper box structure is: 3.4m×2.16m×0.47m (depth×width×height), and is designed in a grid-like form of three transverse reinforcing ribs 13+six longitudinal reinforcing ribs 14, such as Figure 1 As shown in the figure; this structural form forms a structure in which each connection part is under pressure after the external impact force is applied;

[0062] The thickness and material of the newly added transverse reinforcement ribs 13 and longitudinal reinforcement ribs 14 are the same as those of the original box body, which is 30 mm. The transverse reinforcement ribs 13 have two through holes 50, and the longitudinal reinforcement ribs 14 have one through hole 50, in order to effectively reduce the total mass of the bucket without affecting its anti-deformation strength.

[0063] The grid structure and size parameters of the upper box structure are theoretically calculated based on the following:

[0064] During the mining operation of the electric shovel and the process of loading and unloading materials with the bucket, the box body is subjected to alternating stress. The alternating force is dispersed and transmitted through the welds of the ribs, and the stress direction is parallel to the welds. Therefore, we have:

[0065]

[0066] Where: τ 合 is the allowable stress of the weld, τ Q is the shear stress caused by the tensile force F on the box, L is the distance between the tensile force and the bottom plate, τ M is the shear stress caused by the bending moment M formed by the tensile force, K is the weld foot, and h is the weld length (full weld).

[0067] Assuming F = 100N, L = 410mm, the box height, the weld leg = the plate thickness, K = 30mm, and the weld is a full weld. The weld length (on one side) before the transformation is calculated based on the box width, h = 2160mm. The resultant shear stress before the transformation can be calculated as:

[0068] Depend on We can obtain τ M =1255.39(Pa)

[0069] Depend on We can obtain τ Q =1102.30(Pa)

[0070] but

[0071] Similarly, in the new design, h = 2160 + (2016-90) × 2 + 800 × 6 = 10.8 (m). Thus, the shear stress of the middle rib is:

[0072] Depend on We can obtain τ M =50.22(Pa)

[0073] Depend on We can obtain τ Q =220.46(Pa)

[0074] but

[0075] From the above calculations, it can be seen that the shear stress borne by the transverse reinforcement 13 in the design scheme of the present invention is approximately 13.5% of the technical scheme in the prior art with only one transverse reinforcement 13. In other words, the stress-bearing capacity of the upper box structure 10 of the newly designed mining electric shovel bucket structure of the present invention is more than 7 times higher than that of the prior art technical scheme.

[0076] In summary, the present invention provides a mining electric shovel bucket structure and a mining electric shovel bucket processing method. The present invention provides an upper box structure 10 including an upper plate 11, a lower plate 12, a plurality of transverse reinforcing ribs 13 and a plurality of longitudinal reinforcing ribs 14, so that a grid-like support structure distributed transversely along the width direction and longitudinally along the length direction is formed inside the upper box structure 10, that is, the cooperation support between the plurality of transverse reinforcing ribs 13 and the plurality of longitudinal reinforcing ribs 14 significantly improves the overall shear force resistance of the upper box structure 10, thereby improving the overall load-bearing capacity and use of the mining electric shovel bucket structure. Durability, reduces the probability of maintenance, improves the stability and safety of the electric shovel under long-term work, avoids the occurrence of safety hazards, and can obtain obvious economic efficiency and safety benefits in actual use; the present invention solves the common mechanical design defects of the existing upper box body through innovative mechanical structure design of the upper box body structure 10, avoids deformation, cracking and other failures of the upper box body structure 10, and thus ensures the excavation efficiency of the electric shovel equipment; the present invention has a simple structure and low cost, is easy to assemble and form by welding and carry out subsequent maintenance, and is suitable for large-scale promotion and use.

[0077] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0078] Unless otherwise specifically stated, the relative arrangement of the parts and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to actual proportional relationships. The technology, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be considered as a part of the specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of the exemplary embodiments can have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, and therefore, once an item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.

[0079] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0080] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0081] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0082] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A mining electric shovel bucket structure, characterized in that: include: An upper box structure (10), a side wall structure (20) and a lower box structure (30); the mining electric shovel bucket structure has a length direction, a height direction and a width direction that are perpendicular to each other; the side wall structure (20) is respectively connected to the two ends of the upper box structure (10) along the width direction and the two ends of the lower box structure (30) along the width direction; the upper box structure (10) is located above the lower box structure (30) and is used to be connected to an external mechanical arm; a receiving cavity (40) is formed between the side wall structure (20), the upper box structure (10) and the lower box structure (30), and the receiving cavity (40) is used to receive the excavated material; wherein the upper box structure (10) includes an upper plate body (11), a lower plate body (12), a plurality of transverse reinforcing ribs (13) and a plurality of longitudinal reinforcing ribs (14); The two ends of the upper plate (11) along the width direction and the two ends of the lower plate (12) along the width direction are respectively connected to the side wall structure (20); the upper plate (11) is located above the lower plate (12), and the two are arranged in parallel and spaced apart; the extension direction of the transverse reinforcing rib (13) is parallel to the width direction, and the two ends of the transverse reinforcing rib (13) along the height direction are fixedly connected to the upper plate (11) and the lower plate (12); the extension direction of the longitudinal reinforcing rib (14) is parallel to the length direction, and the two ends of the longitudinal reinforcing rib (14) along the height direction are fixedly connected to the upper plate (11) and the lower plate (12); a plurality of the transverse reinforcing ribs (13) are arranged in parallel and spaced apart along the length direction, and a plurality of the longitudinal reinforcing ribs (14) are arranged in parallel and spaced apart along the width direction.

2. The mining electric shovel bucket structure according to claim 1, characterized in that: The transverse reinforcing rib (13) is fixedly connected to the side wall structure (20) at both ends along the width direction; and the longitudinal reinforcing rib (14) is fixedly connected to the transverse reinforcing rib (13) at one end or both ends along the length direction.

3. The mining electric shovel bucket structure according to claim 1, characterized in that: The plurality of transverse reinforcing ribs (13) are projected along the length direction, and the projections of the plurality of reinforcing ribs overlap; and / or the plurality of longitudinal reinforcing ribs (14) are divided into a plurality of groups, and the plurality of longitudinal reinforcing ribs (14) in each group are projected along the length direction, and the projections of the plurality of longitudinal reinforcing ribs (14) in the same group overlap.

4. The mining electric shovel bucket structure according to claim 1, characterized in that: The transverse reinforcing ribs (13) and the longitudinal reinforcing ribs (14) are each provided with at least one through hole (50) to reduce weight; the two ends of the upper plate body (11) along the width direction and the two ends of the lower plate body (12) along the width direction are respectively fixedly connected to the side wall structure (20) by welding; the two ends of the transverse reinforcing ribs (13) along the height direction are respectively fixedly connected to the upper plate body (11) and the lower plate body (12) by welding; the two ends of the longitudinal reinforcing ribs (14) along the height direction are respectively fixedly connected to the upper plate body (11) and the lower plate body (12) by welding.

5. The mining electric shovel bucket structure according to claim 4, characterized in that: The through hole (50) is a waist-shaped hole, and the through hole (50) on the transverse reinforcing rib (13) and the through hole (50) on the longitudinal reinforcing rib (14) are of the same size; the transverse reinforcing rib (13) has two through holes (50), and the two through holes (50) are symmetrically arranged relative to the first vertical plane. The distance between the centroid positions of the two through holes (50) is not less than half of the size of the transverse reinforcing rib (13) in the width direction, and the two ends of the transverse reinforcing rib (13) along the width direction are symmetrically arranged relative to the first vertical plane; the longitudinal reinforcing rib (14) has one through hole (50), and the through hole (50) is symmetrically arranged relative to the second vertical plane. The two ends of the longitudinal reinforcing rib (14) along the length direction are symmetrically arranged relative to the second vertical plane.

6. The mining electric shovel bucket structure according to claim 1, characterized in that: At least one of the transverse reinforcing ribs (13), the longitudinal reinforcing ribs (14), the upper plate body (11) and the lower plate body (12) is made of at least one of the alloy materials with grades of Q345A, Mn13, Mn14, Mn13Cr2 and ZGMn13; the distance between two adjacent longitudinal reinforcing ribs (14) is not greater than 600 mm; the distance between two adjacent transverse reinforcing ribs (13) is not greater than 900 mm; the thickness of the upper plate body (11) and the lower plate body (12) is not less than 16 mm.

7. A method for processing a mining electric shovel bucket, characterized in that: The mining electric shovel bucket processing method is used to process the mining electric shovel bucket structure according to any one of claims 1 to 6, and the mining electric shovel bucket processing method comprises the following steps: S1. Performing root cleaning and grinding processing on the positions where the upper box structure (10), the side wall structure (20), and the lower box structure (30) need to be welded; then welding and fixing the side wall structure (20) and the lower box structure (30) at both ends along the width direction; S2, respectively welding and fixing the two ends of the lower plate (12) along the width direction to the side wall structure (20), and then sequentially welding and fixing the plurality of transverse reinforcing ribs (13) to the lower plate (12); when welding each transverse reinforcing rib (13), welding is performed simultaneously from both ends of the transverse reinforcing rib (13) along the width direction in opposite directions, and controlling the extension direction of the weld to be parallel to the width direction; S3, sequentially welding and fixing the plurality of longitudinal reinforcing ribs (14) to the lower plate (12), and welding and fixing one or both ends of each longitudinal reinforcing rib (14) to the adjacent transverse reinforcing rib (13) along the length direction; S4. Welding and fixing the two ends of the upper plate body (11) along the width direction to the side wall structure (20), and then sequentially welding and fixing the plurality of transverse reinforcing ribs (13) and the plurality of longitudinal reinforcing ribs (14) to the upper plate body (11).

8. The mining electric shovel bucket processing method according to claim 7, characterized in that: In at least one of step S1, step S2, step S3 and step S4, after welding is completed, a heat preservation treatment is performed, and the temperature range of the weld position is controlled to be 150° C. to 200° C., and the heat preservation time is within the range of 2 to 2.5 hours.

9. The mining electric shovel bucket processing method according to claim 7, characterized in that: In at least one of step S1, step S2, step S3, and step S4, the welding position is preheated during welding, and the preheating temperature range is 120° C.±5° C. During welding, the interlayer temperature is controlled to be no greater than 200° C. to ensure the quality of the weld; And / or, in at least one of step S1, step S2, step S3 and step S4, carbon dioxide gas shielded welding is used as the welding method, low-carbon flux-cored wire is selected as the solder, and ultrasonic flaw detection is performed on the weld position after welding, and the defective position is polished and cleaned with an angle grinder before repair welding.

10. The mining electric shovel bucket processing method according to claim 9, characterized in that: In at least one of step S1, step S2, step S3 and step S4, a base laying step, a filling step and a covering step are sequentially performed each time welding; in the base laying step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 26-27 V, the current is in the range of 180-210 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.2-0.25 m / min; in the filling step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 27-29 V, the current is in the range of 210-250 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.25-0.3 m / min; in the covering step, the welding wire diameter is 1.6 mm, the welding voltage is in the range of 27-28 V, the current is in the range of 180-210 A, the carbon dioxide gas flow rate is in the range of 15-20 L / min, and the welding speed is controlled within 0.2-0.25 m / min.

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