Method for filling counterweight material of forklift counterweight
Through the drying process and shocking platform vibration technology, the problem of long production cycle and serious pollution in the ink -to -balance -dampness method in the forklift balance and wetting method is solved. stability.
Patent Information
- Application Number
- CN202411491268.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-24
- Publication Date
- 2025-01-28
AI Technical Summary
The existing forklift balanced weight wet filling process has problems such as long production cycle, serious pollution, unsafe weight and unqualified paint surface.
Use dry material irrigation process, use the mixture of ice, copper and iron and sulfur powder as the filling material, and fully fill in the filling process through the high -frequency vibration of the shocking platform, cancel the drying process, directly seal the welding and spraying process. Essence
The quality of balanced and heavy irrigation is stable, efficient in production, no pollution, reduced manufacturing costs, improved the working environment, and improved the quality stability of the forklift balance.
Smart Images
Figure CN119368678A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of a filling method for a counterweight material of an engineering machinery counterweight, in particular to a filling method for a counterweight material of a forklift counterweight. Background Art
[0002] Forklift is an important equipment used for handling and stacking items. Therefore, it is necessary to add a certain amount of weight to the forklift frame through counterweights to ensure the stability and carrying capacity of the forklift, thereby ensuring its stability and safety during work. Although solid cast iron counterweights can meet the weight requirements, the high material cost leads to high manufacturing costs. Therefore, most of the composite counterweights on the market are used, that is, hollow counterweights are used and filled with fillers. This composite counterweight can not only meet the weight requirements of forklifts for counterweights, but also has a much lower manufacturing cost than solid counterweights.
[0003] The commonly used filling method for existing forklift composite counterweights is to use barite, iron ore, etc. as fillers, cement as a binder, and add an appropriate amount of water to mix. Because the mixture is in a slurry state and has good fluidity, it is generally filled on a vibration table until the required weight is reached. Because the filling material has a high water content, it needs to be transferred to a drying room after filling to dry until the water in the counterweight is completely volatilized without weight loss, and then it can be transferred to the next process such as sealing and shot blasting. The defects are: first, the production cycle of the counterweight of this process is long and the efficiency is low; second, the composite counterweight shell generally uses QT400 castings, and the density of the casting material is poor. After the counterweight is sprayed and painted, if the water is not dried thoroughly, there will be problems such as substandard weight loss, bubbling, delamination, cracking and discoloration of the paint surface; third, the traditional filling process requires the addition of a large amount of water to mix the ingredients, which easily causes the mixed ingredients and sewage to flow everywhere, and the filling workshop is dirty and messy, affecting the working environment. Summary of the invention
[0004] The purpose of the present invention is to provide a method for filling forklift counterweight materials with stable counterweight filling quality, efficient production and pollution-free, so as to solve the problems of long production cycle, serious pollution, weight guarantee failure and unqualified paint surface in the existing forklift counterweight wet filling.
[0005] To achieve the above objectives, a method for filling a forklift counterweight with a weight material according to the present invention comprises the following steps:
[0006] SO, a filling port is set on each level platform of the counterweight hollow shell casting 1 according to the width of the platform. The area of the filling port should be large enough to ensure smooth filling of dry filler;
[0007] S1 Balance weight empty shell weighing: Use a weighing two-dimensional filling and vibrating table, the upper table is equipped with a special empty shell weighing and positioning tooling, hoist and fix the balance weight empty shell casting 1 on the vibrating table tooling, with the filling hole facing upwards, and weigh the actual gross weight of the balance weight empty shell casting 1 through the automatic digital display weighing device equipped with the vibrating table;
[0008] S2 filler material preparation: A mixture of matte iron and sulfide iron powder is used as filler, and the materials are prepared according to the mass ratio of matte iron: sulfide iron powder = 7:3, wherein the particle size of matte iron is 15mm~50mm, and the drainage specific gravity is 6.8g / cm 3 ~6.9g / cm 3 The particle size of ferrous sulfide powder is 80 mesh to 200 mesh, and the drainage specific gravity is 5.0g±0.1g / cm 3 ; Then, according to the weight of the empty shell casting 1 of the counterweight, calculate the weight of the filling material according to the counterweight weight requirements and prepare the corresponding materials;
[0009] S3 filling and vibrating: Fill the prepared filling material into the inner cavity of the counterweight hollow shell casting 1 in multiple times, and use the high-frequency vibration of the vibrating table to fully fill the filling material;
[0010] S4 Confirmation of total weight of balancing weight after filling: After filling, confirm whether the total weight of balancing weight meets the requirements. If not, rework and make corrections;
[0011] S5 Sealing and welding: After completing the filling of the counterweight, directly seal and weld and flow to the next puttying and spraying process.
[0012] The filling ports of the SO on the counterweight hollow shell casting 1 are set as follows: the low-level platform is provided with a circular filling port 1-1 due to the width of the table; other platforms are provided with rectangular filling ports due to the limitation of the table width, including a middle-high square filling port 1-2, a right-high square filling port 1-3, a left-high square filling port 1-5 and a rear-second-high square filling port 1-4.
[0013] The S3 filling and vibrating filling is to fill the prepared filling material into the inner cavity of the counterweight in five times:
[0014] (1) First filling: Add materials from the low circular filling port 1-1 and the middle and high square filling port 1-2 at the turning part. First add 12% of matte iron, then add 16% of sulfide iron powder. The sulfide iron powder can fully fill the gaps between the matte iron and make the filling material fill the bottom cavity of the L-shaped turning part and fill the sharp corners of the bottom surface.
[0015] (2) Second feeding and filling: feed from the low circular filling port 1-1 and the middle and high square filling port 1-2 at the turning part, first add 18% of matte iron, then add 16% of ferrous sulfide powder, and fully vibrate to fill the lower volume of the L-shaped turning part;
[0016] (3) The third time of adding materials and filling: Add materials from the right high square filling port 1-3, the second high square filling port 1-4, and the left high square filling port 1-5. First add 25% of matte iron, and then add 23% of sulfide iron powder. During the filling process, prevent the matte iron from being stuck by the reinforcing ribs, and fully vibrate it to fill it to the lower horizontal surface of the L-shape.
[0017] (4) The fourth filling: add materials from the right high square filling port 1-3, the second high square filling port 1-4, and the left high square filling port 1-5. First add 23% ferrous sulfide powder, then add 25% matte iron, and fully vibrate to fill the filling material to the plane position of the middle high square filling port 1-2;
[0018] (5) The fifth time of filling: add materials from the right high square filling port 1-3, the second high square filling port 1-4, and the left high square filling port 1-5. First add 20% of matte iron, then add 22% of ferrous sulfide powder, and fully shake them.
[0019] The present invention provides a method for filling a forklift counterweight with a weight material, which has the following technical features and beneficial effects:
[0020] 1. Through the study of the filling process of dry materials for counterweights, suitable fillers and proportions are selected, and a mixture of matte iron and ferrous sulfide powder is used as the filler. At the same time, a reasonable vibration filling process is implemented to ensure sufficient stacking density so as to fill a counterweight that meets the requirements.
[0021] 2. By selecting matte iron and ferrous sulfide powder as dry fillers and selecting appropriate particle size, the situation of material jamming and filling channel blockage caused by the complex shape of the inner cavity of the counterweight, many turns and narrow local space during the filling process can be avoided.
[0022] 3. The dry material filling process has the advantages of short production cycle, stable counterweight quality and environmentally friendly production.
[0023] 4. A large part of the dry material of the mixture of matte iron and ferrosulfur powder comes from industrial waste. The cost of raw materials is low. Waste recycling not only reduces production costs, but also has good social benefits.
[0024] The present invention adopts a dry material filling process to replace the traditional filling process of adding water and adhesive to mix fillers in the prior art, and directly fills the dry fillers into the cavity of the composite counterweight block, thereby eliminating the counterweight block drying process and reducing the line side inventory; the entire process from filling to painting can be operated continuously, the flow between processes is fast, and the production line occupies a small factory area; the final weight of the counterweight block can be accurately controlled; the operating efficiency can be greatly improved, the manufacturing cost can be reduced, and the working environment can be greatly improved. In addition, the counterweight does not have to be mixed with water, the inner cavity is dry, and the surface can be directly sprayed with paint, and the paint surface will not cause quality problems due to the failure to dry the internal moisture of the filler, which greatly improves the quality stability of the forklift counterweight. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Figure 1 The invention discloses a structural schematic diagram of a hollow shell casting of a counterweight in a method for filling counterweight material of a forklift counterweight.
[0026] Figure 2 The present invention is a schematic diagram of a state in which a counterweight hollow shell casting is filled with dry filling material in a method for filling counterweight material for a forklift counterweight of the present invention.
[0027] Figure numerals: counterweight hollow shell casting 1, low circular filling port 1-1, middle high square filling port 1-2, right high square filling port 1-3, left high square filling port 1-5, rear second high square filling port 1-4, feeding hopper 2. DETAILED DESCRIPTION
[0028] The following is a further detailed description of a method for filling a forklift counterweight with a weight material in conjunction with the accompanying drawings and specific embodiments of the present invention.
[0029] The following is a specific example of a 3T forklift counterweight. The weight of the counterweight hollow shell casting 1 is about 492kg, and the inner cavity volume is 0.266m 3 The total weight after filling is required to be 1700-1730kg, so the filling weight must be about 1208kg, and the theoretical bulk density must not be less than 4.54g / cm 3 .
[0030] Figure 1-Figure 2 As shown, a method for filling a forklift counterweight with a weight material according to the present invention comprises the following steps:
[0031] SO sets filling ports on various height platforms of the counterweight hollow shell casting 1 according to the width of the platform, and the area of the filling ports must be sufficient to ensure smooth filling of dry filler; the filling ports of SO on the counterweight hollow shell casting 1 are set as follows: the low-level platform is provided with a circular filling port 1-1 due to the width of the table; other platforms are provided with rectangular filling ports due to the limitation of the table width, including the middle-high square filling port 1-2, the right-high square filling port 1-3, the left-high square filling port 1-5 and the rear-second-high square filling port 1-4.
[0032] S1 counterweight empty shell weighing: select a weighing two-dimensional filling and vibrating table, the upper table is equipped with a special empty shell weighing and positioning tooling, use a crane to lift the counterweight empty shell casting 1 and fix it on the vibrating table tooling, so that the filling hole faces upwards, the vibrating table is equipped with an automatic digital weighing device, the weight is "set to zero" before lifting, and the actual gross weight of the counterweight empty shell casting 1 can be directly read after lifting.
[0033] S2 Filling Material Preparation: Due to the complex shape of the inner cavity of the counterweight, many turns and narrow local space, in order to avoid material jamming and blocking of the filling channel during the filling process, and considering the cost of raw materials, matte iron and sulfide iron powder are selected as dry fillers, and the appropriate particle size is selected to facilitate the smooth filling of materials during the filling process; among them, the particle size of matte iron is required to be 15mm~50mm, and the drainage specific gravity is 6.8g / cm 3 ~6.9g / cm 3 ; The particle size of ferrous sulfide powder should be 80-200 mesh, and the drainage specific gravity should be 5.0g±0.1g / cm 3 To ensure that the weight requirements are met, the filling ratio adopted is 70% matte iron and 30% ferrosulphide powder by mass, that is, the actual bulk density is 5.0g / cm 3 Then, according to the actual weight of the counterweight hollow shell casting 1, the weight of the filling material is calculated according to the counterweight weight requirements and the corresponding materials are prepared.
[0034] S3 filling and vibrating: Place the hopper 2 on the counterweight hollow shell casting 1, and align the discharge port of the hopper 2 with the counterweight hollow shell casting 1, so that the dry filler in the hopper 2 falls into the filling hole, turn on the vibrating table, and use the high-frequency vibration of the vibrating table to fully fill the filler. Since the dry filler has flow characteristics, it can be filled into various parts of the hollow shell by vibrating the counterweight hollow shell casting 1 and the filler, and after the vibration, the filler has appropriate compactness and density; add the prepared filler into the inner cavity of the counterweight hollow shell casting 1 in five times for filling and vibrating:
[0035] (1) First filling: Add materials from the low circular filling port 1-1 and the middle and high square filling port 1-2 at the turning part. First add 12% of matte iron, then add 16% of sulfide iron powder. The sulfide iron powder can fully fill the gaps between the matte iron and make the filling material fill the bottom cavity of the L-shaped turning part and fill the sharp corners of the bottom surface.
[0036] (2) Second feeding and filling: feed from the low circular filling port 1-1 and the middle and high square filling port 1-2 at the turning part, first add 18% of matte iron, then add 16% of ferrous sulfide powder, and fully vibrate to fill the lower volume of the L-shaped turning part;
[0037] (3) The third time of adding materials and filling: Add materials from the right high square filling port 1-3, the second high square filling port 1-4, and the left high square filling port 1-5. First add 25% of matte iron, and then add 23% of sulfide iron powder. During the filling process, prevent the matte iron from being stuck by the reinforcing ribs, and fully vibrate it to fill it to the lower horizontal surface of the L-shape.
[0038] (4) The fourth filling: add materials from the right high square filling port 1-3, the second high square filling port 1-4, and the left high square filling port 1-5. First add 23% ferrous sulfide powder, then add 25% matte iron, and fully vibrate to fill the filling material to the plane position of the middle high square filling port 1-2;
[0039] (5) The fifth time of filling: add materials from the right high square filling port 1-3, the second high square filling port 1-4, and the left high square filling port 1-5. First add 20% of matte iron, then add 22% of ferrous sulfide powder, and fully shake them.
[0040] S4 Confirmation of total weight of counterweight after filling: After filling is completed, turn off the vibration motor and inflation valve of the compaction table, and read the weight directly after the compaction table is lowered into place to confirm whether the total weight of the counterweight meets the requirements. If not, rework and correct it.
[0041] S5 Sealing and welding: After completing the filling of the counterweight, directly seal and weld and flow to the next puttying and spraying process.
[0042] The above-mentioned tooling for adding materials from the low circular filling port 1-1, the middle and high square filling port 1-2 and the rear second high square filling port 1-4 adopts other common tooling, which is no longer marked in the drawings.
Claims
1. A method for filling a forklift counterweight with a weight material, characterized by: The following steps are involved: SO, a filling port is arranged on each level platform of the counterweight hollow shell casting (1) according to the width of the platform, and the area of the filling port should be large enough to ensure smooth filling of dry filler; S1 Weighing the empty shell of the counterweight: A two-dimensional filling and vibrating weighing table is used, and a special empty shell weighing and positioning tool is provided on the upper surface of the table. The empty shell casting (1) of the counterweight is hoisted and fixed on the vibrating table tool with the filling hole facing upwards. The actual gross weight of the empty shell casting (1) of the counterweight is weighed by the automatic digital display weighing device equipped with the vibrating table; S2 filler material preparation: A mixture of matte iron and sulfide iron powder is used as filler, and the materials are prepared according to the mass ratio of matte iron: sulfide iron powder = 7:3, wherein the particle size of matte iron is 15mm~50mm, and the drainage specific gravity is 6.8g / cm 3 ~6.9g / cm 3 The particle size of ferrous sulfide powder is 80 mesh to 200 mesh, and the drainage specific gravity is 5.0g±0.1g / cm 3 ; Then, according to the weight of the empty shell casting (1) of the counterweight, the weight of the filling material is calculated according to the counterweight weight requirements and the corresponding materials are prepared; S3 filling and vibrating: filling the prepared filling material into the inner cavity of the counterweight hollow shell casting (1) in multiple times, and using the high-frequency vibration of the vibrating table to fully fill the filling material; S4 Confirmation of total weight of balancing weight after filling: After filling, confirm whether the total weight of balancing weight meets the requirements. If not, rework and make corrections; S5 Sealing and welding: After completing the filling of the counterweight, directly seal and weld and flow to the next puttying and spraying process.
2. The method for filling the forklift counterweight material as claimed in claim 1, characterized in that: The filling ports of the SO on the counterweight hollow shell casting (1) are arranged as follows: a circular filling port (1-1) is arranged on the low platform due to the width of the table top; and rectangular filling ports are arranged on other platforms due to the limitation of the table top width, including a middle high position square filling port (1-2), a right high position square filling port (1-3), a left high position square filling port (1-5) and a rear second high position square filling port (1-4).
3. The method for filling the forklift counterweight material as claimed in claim 1, characterized in that: The S3 filling and vibrating filling is to fill the prepared filling material into the inner cavity of the counterweight in five times: (1) First filling: Add materials from the low circular filling port (1-1) and the middle and high square filling port (1-2) at the turning part. First add 12% of matte iron, then add 16% of ferrous sulfide powder. The ferrous sulfide powder can fully fill the gaps between the matte iron and allow the filling material to fill the bottom cavity of the L-shaped turning part and fill the sharp corners of the bottom surface. (2) Second feeding and filling: feeding from the low circular filling port (1-1) and the middle and high square filling port (1-2) at the turning part, first add 18% of matte iron, then add 16% of ferrous sulfide powder, and fully shake to fill the lower volume of the L-shaped turning part; (3) The third time of adding materials and filling: Add materials from the right high square filling port (1-3), the second high square filling port (1-4), and the left high square filling port (1-5). First, add 25% of matte iron, and then add 23% of ferrous sulfide powder. During the filling process, prevent the matte iron from being stuck by the reinforcing ribs, and fully vibrate it to fill it to the lower horizontal surface of the L-shape. (4) The fourth time of filling: add materials from the right high-position square filling port (1-3), the second high-position square filling port (1-4), and the left high-position square filling port (1-5), first add 23% of ferrous sulfide powder, then add 25% of matte iron, and fully vibrate to fill the filling material to the plane position of the middle high-position square filling port (1-2); (5) The fifth time of adding materials and filling: Add materials from the right high-position square filling port (1-3), the second high-position square filling port (1-4), and the left high-position square filling port (1-5). First, add 20% of matte iron, and then add 22% of ferrous sulfide powder, and fully shake them.