Guide wheel manufacturing method and guide wheel

Abstract

The present invention relates to the technical field of idler wheels, and discloses a manufacturing method of an idler wheel and the idler wheel. The manufacturing method of the idler wheel includes: bending a part of the outer circle of the first spoke plate by a first preset angle, and bending a part of the outer circle of the second spoke plate by a second preset angle; opening a first annular groove in the inner circle at one axial end of the rim, and opening a second annular groove in the inner circle at the other axial end of the rim; first welding and fixing the first spoke plate to the first annular groove and the hub respectively, and then welding and fixing the second spoke plate to the second annular groove and the hub respectively. By changing the bending angle of the outer circle of the spoke plate, the first pre-deformation can be manufactured. By changing the depth of the first annular groove in the axial direction, the second pre-deformation can be manufactured. By a predetermined welding sequence, the third pre-deformation can be manufactured during the welding process. By superimposing the three pre-deformations, after the heat treatment of the idler wheel is completed, the end faces of the hubs are all higher than the end faces of the rim, so that the idler wheel can carry out subsequent machining processes.

Description

Technical Field

[0001] The present invention relates to the technical field of idlers, and particularly to a manufacturing method of an idler and an idler. Background Art

[0002] The idler is an important component in the traveling device of a hydraulic construction machine, and is widely used in hydraulic excavators and bulldozers. It is an important unit of the traveling and supporting system of a crawler construction machine. Among them, the wheel body of the idler is divided into three structures: welded type, integral forging type, and integral casting type. The welded wheel body is composed of a rim, a hub, and a web. During the manufacturing process of the welded wheel body, due to inevitable deformation in the welding and heat treatment processes, after the deformation amounts of the two steps are superimposed, the hub will eventually shift relative to the rim. The deformation problem of the welded wheel body greatly limits the reliability and durability of this type of wheel body.

[0003] Currently, in the manufacturing process of the existing welded wheel body, the deformation problem of the wheel body is mainly solved by the method of forced straightening. After the heat treatment of the wheel body is completed, the rim of the wheel body is lifted from below by a straightening device and pressure is applied to the hub from above to change the relative position of the two, thereby improving the misalignment of the hub. Although this rectification method can improve the deformation of the wheel body, large stresses will be generated at the weld of the wheel body during the forced straightening process. Even if the weld of the wheel body does not crack during the forced straightening process, when the wheel body is assembled and working, after the residual stress at the weld is superimposed with the working stress, there is still a situation where the wheel body is prone to cracking, and the reliability and durability of the wheel body are still poor. Summary of the Invention

[0004] In view of this, the present invention provides a manufacturing method of an idler and an idler to solve the problem of poor improvement effect of the existing deformation solution method for welded idlers.

[0005] In a first aspect, the present invention provides a manufacturing method of an idler. The idler includes a rim, a hub, a first web, and a second web. The manufacturing method of the idler includes:

[0006] Bending a part of the outer circle of the first web by a first preset angle, and bending a part of the outer circle of the second web by a second preset angle;

[0007] Opening a first annular groove in the inner circle at one axial end of the rim, and opening a second annular groove in the inner circle at the other axial end of the rim;

[0008] First, welding and fixing the first web to the first annular groove and the hub respectively, and then welding and fixing the second web to the second annular groove and the hub respectively.

[0009] Beneficial effects: By changing the bending angle of the outer ring of the web plate, the first pre-deformation can be created. By changing the axial depth of the first annular groove, the second pre-deformation can be created. By a predetermined welding sequence, the third pre-deformation can be created during the welding process. By superimposing the three pre-deformations, after the idler wheel is heat-treated, the end faces of the hub are all higher than the end faces of the rim, enabling the idler wheel to undergo subsequent machining processes. Additionally, since the total pre-deformation amount is formed by the three pre-deformations together, the total pre-deformation amount can be flexibly adjusted by adjusting any one of the pre-deformation amounts, facilitating flexible adaptation to idler wheels of various specifications and effectively solving the problem of poor improvement effect of the deformation solution method for existing welded idler wheels.

[0010] In an alternative embodiment, the steps of first welding the first web plate to the first annular groove and the hub respectively, and then welding the second web plate to the second annular groove and the hub respectively include:

[0011] Spot-weld the first web plate to the first annular groove and the hub respectively, and spot-weld the second web plate to the second annular groove and the hub respectively; first perform full welding on the inner ring of the first web plate and the hub, and then perform full welding on the outer ring of the first web plate and the first annular groove; first perform full welding on the outer ring of the second web plate and the second annular groove, and then perform full welding on the inner ring of the second web plate and the hub.

[0012] Beneficial effects: Using such welding steps for welding can, on the basis of making the end face of the hub protrude from the end face of the rim, reduce the difference in the protruding amounts of the two end faces of the hub, improve the consistency of the end faces of the two ends of the hub protruding from the end face of the rim, not only ensure the minimum machining allowance on the subsequent automated machining line, avoid black skin residue, but also avoid tool breakage caused by excessive machining allowance, reduce tool loss, and ensure the production efficiency of the automated machining line.

[0013] In an alternative embodiment, the first preset angle is less than or equal to the second preset angle.

[0014] Beneficial effects: When there is a difference between the first preset angle and the second preset angle, the pre-deformation amount can be more significantly increased.

[0015] In an alternative embodiment, the axial depth of the first annular groove is the first preset depth, the axial depth of the second annular groove is the second preset depth, and the first preset depth is less than or equal to the second preset depth.

[0016] Beneficial effects: When there is a difference between the first preset depth and the second preset depth, the pre-deformation amount can be more significantly increased.

[0017] In an alternative embodiment, after the steps of first welding the first web plate to the first annular groove and the hub respectively, and then welding the second web plate to the second annular groove and the hub respectively, the following steps are further included:

[0018] The guide wheel that has completed welding is subjected to intermediate frequency induction heating by a heating device, and the guide wheel is quenched.

[0019] Beneficial effects: Through the intermediate frequency quenching step, the strength and wear resistance of the guide wheel that has completed welding can be further improved, and the stress condition therein can be improved.

[0020] In an alternative embodiment, the steps of subjecting the guide wheel that has completed welding to intermediate frequency induction heating by a heating device and quenching the guide wheel include:

[0021] The end rim tread where the first spoke plate of the rim of the guide wheel is located is heated by a heating device, and the guide wheel is subjected to the first cooling quenching.

[0022] The end rim tread where the second spoke plate of the rim of the guide wheel is located is heated by a heating device, and the guide wheel is subjected to the second cooling quenching.

[0023] Beneficial effects: Through this quenching step, the difference in the protrusion amount of the two end faces of the hub can be further reduced on the previous basis, and the consistency of the end faces of the two ends of the hub protruding from the end face of the rim can be improved.

[0024] In an alternative embodiment, the hub has a through hole extending axially therein;

[0025] The heating device includes an induction heater and a rotatable positioning assembly. The positioning assembly includes an axially positioning rotary tray and a radially positioning central pin. The axially positioning rotary tray has three bearing surfaces spaced 120°, and the bearing surfaces are used for abutting and cooperating with the end face of the rim. The radially positioning central pin is arranged on the axially positioning rotary tray and is coaxially arranged with the axially positioning rotary tray. The radially positioning central pin is inserted and cooperated with the through hole of the hub.

[0026] Beneficial effects: Using this form of heating device, through the axial positioning of the radially positioning central pin and the through hole, it can be ensured that the guide wheel does not have any radial runout in any orientation during rotation, stabilizing the radial runout of the wheel body tread. Through the end face positioning of the bearing surface of the axially positioning rotary tray and the rim, the possibility of the guide wheel shaking during rotation can be further reduced, effectively improving the heat uniformity of the guide wheel during rotation, and ensuring the consistency and controllability of further deformation of the guide wheel after heat treatment.

[0027] In an alternative embodiment, the steps of subjecting the guide wheel that has completed welding to intermediate frequency induction heating by a heating device and quenching the guide wheel include:

[0028] The rim tread at one end where the first spoke plate of the rim is located is heated to 850 - 900 °C by a heating device, and the heating time range is 145 - 465 S;

[0029] Lower the guide wheel into the quenching water tank for immersion spray quenching. The water spraying time ranges from 120 to 140 s, the water spraying pressure ranges from 0.1 to 0.3 MPa, the water spraying flow rate ranges from 55 to 75 m³ / h, and the final quenching hardness is ≥51 HRC;

[0030] Heat the tread of the rim at one end where the second spoke of the rim is located to 850 - 900 °C through a heating device, and the heating time ranges from 145 to 465 s;

[0031] Lower the guide wheel into the quenching water tank for immersion spray quenching. The water spraying time ranges from 120 to 140 s, the water spraying pressure ranges from 0.1 to 0.3 MPa, the water spraying flow rate ranges from 55 to 75 m³ / h, and the final quenching hardness is ≥51 HRC.

[0032] Beneficial effects: The quenching step is simple and effective, which can effectively improve the overall structural strength of the guide wheel and the wear resistance of the tread of the rim.

[0033] In an alternative embodiment, after the steps of performing medium-frequency induction heating on the completed welded guide wheel through a heating device and quenching the guide wheel, the following steps are further included:

[0034] Perform low-temperature tempering on the guide wheel. The tempering temperature ranges from 190 to 210 °C, and the tempering time ranges from 1.5 h to 2.5 h, so that the tread hardness of the rim after tempering of the guide wheel is controlled within 48 - 58 HRC.

[0035] Beneficial effects: While eliminating the internal stress of the guide wheel through the tempering step, it can also further adjust the hardness of the rim to prevent cracking and improve strength and wear resistance.

[0036] In a second aspect, the present invention also provides a guide wheel manufactured by the above-mentioned guide wheel manufacturing method, including: a rim, a hub, and a first spoke and a second spoke. The hub is fixedly connected to the rim through the first spoke and the second spoke respectively. Description of the Drawings

[0037] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the specific embodiments or the prior art. Obviously, the following drawings are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0038] Figure 1 Schematic diagram of the main steps of a guide wheel manufacturing method according to an embodiment of the present invention;

[0039] Figure 2 is Figure 1 a schematic diagram showing the steps of the guide wheel manufacturing method as shown;

[0040] Figure 3 is Figure 1 a schematic sectional view of the guide wheel in the guide wheel manufacturing method as shown;

[0041] Figure 4 is Figure 1 a schematic sectional view of the guide wheel when it is cooperating with the heating device as shown.

[0042] Explanation of reference numerals:

[0043] 1, rim; 101, first annular groove; 102, second annular groove; 103, first tread segment; 104, protruding segment; 105, second tread segment;

[0044] 2, hub; 201, through hole; 3, first spoke; 4, second spoke;

[0045] 5, heating device; 501, induction heater; 502, positioning component; 5021, axial positioning rotary tray; 5022, radial positioning center pin; 5023, bearing surface. Detailed implementation manners

[0046] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some but not all of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative efforts fall within the protection scope of the present invention.

[0047] The following combines Figures 1 to 4 , to describe the embodiments of the present invention.

[0048] In the related art, in order to improve the deformation problem of a welded wheel body, during the welding process of the wheel body, an offset is usually created in advance by misaligning the rim and the hub to produce a reverse offset amount, thereby offsetting the deformation problem of the wheel body after welding and heat treatment. However, in the actual production process, after the welded wheel body has completed the welding and heat treatment processes, machining of both end faces of the wheel body is still required. At this time, the end face of the hub needs to be higher than the end face of the rim in order to perform machining. When the end face of the hub is lower than the end face of the rim, it means that the wheel body after the welding and heat treatment processes is unqualified. Although the above improvement method can offset part of the deformation of the wheel body during the welding and heat treatment processes to a certain extent, for the wheel body under this improvement method, the end face of one end of the hub will still be lower than the end face of the rim. For example, before improvement, the end face of one end of the hub was 5 mm lower than the end face of the rim, and the end face of the other end of the hub was 7 mm higher than the end face of the rim. After adopting the above improvement method, the end face of one end of the hub can be 1 mm lower than the end face of the rim, and the end face of the other end of the hub can be 3 mm higher than the end face of the rim. Although the amount of deformation is reduced, the wheel body is still unqualified.

[0049] According to an embodiment of the present invention, on the one hand, a method for manufacturing a guide wheel is provided. The guide wheel includes a rim 1, a hub 2, and a first spoke 3 and a second spoke 4. The method for manufacturing the guide wheel includes:

[0050] Bending a part of the outer ring of the first spoke 3 by a first preset angle and bending a part of the outer ring of the second spoke 4 by a second preset angle;

[0051] Opening a first annular groove 101 in the inner ring at one axial end of the rim 1 and opening a second annular groove 102 in the inner ring at the other axial end of the rim 1;

[0052] First, welding the first spoke 3 to the first annular groove 101 and the hub 2 respectively, and then welding the second spoke 4 to the second annular groove 102 and the hub 2 respectively.

[0053] Applying the method for manufacturing the guide wheel of this embodiment, a first pre-deformation can be created by changing the bending angle of the outer ring of the spoke, a second pre-deformation can be created by changing the depth of the first annular groove 101 in the axial direction, and a third pre-deformation can be created during the welding process by a predetermined welding sequence. By superimposing the three pre-deformations, after the guide wheel has completed heat treatment, the end face of the hub 2 can be higher than the end face of the rim 1, so that the guide wheel can undergo subsequent machining processes. In addition, since the three pre-deformations together form the total pre-deformation amount, the total pre-deformation amount can be flexibly adjusted by adjusting any one of the pre-deformation amounts, so as to flexibly adapt to guide wheels of various specifications and models, effectively solving the problem of poor improvement effect of the existing deformation solution method for welded guide wheels.

[0054] Among them, it should be noted that in the steps of first welding the first web plate 3 to the first annular groove 101 and the hub 2 respectively, and then welding the second web plate 4 to the second annular groove 102 and the hub 2 respectively, the welding here refers to the formal welding process except for positioning steps such as spot welding.

[0055] That is: after the first web plate 3 is completely welded, the remaining welding steps are carried out on the second web plate 4. It is not that after the first web plate 3 and the second web plate 4 are spot welded, the first welding step is carried out on the first web plate 3, the first welding step is carried out on the second web plate 4, then the second welding step is carried out on the first web plate 3, and the second welding step is carried out on the second web plate 4. The welding method of this embodiment can not only shorten the time required for the welding process, but also further improve the qualified rate of the guide wheel.

[0056] In addition, it should be noted that the first preset angle, the second preset angle, the size of the first annular groove 101, and the size of the second annular groove 102 are not limited. Since there are many specification sizes of the guide wheel, different specification sizes of the guide wheel need to use corresponding angle and annular groove sizes.

[0057] In a possible implementation manner, the steps of first welding the first web plate 3 to the first annular groove 101 and the hub 2 respectively, and then welding the second web plate 4 to the second annular groove 102 and the hub 2 respectively include:

[0058] Spot weld the first web plate 3 to the first annular groove 101 and the hub 2 respectively, and spot weld the second web plate 4 to the second annular groove 102 and the hub 2 respectively;

[0059] First, perform full welding on the inner ring of the first web plate 3 and the hub 2, and then perform full welding on the outer ring of the first web plate 3 and the first annular groove 101;

[0060] First, perform full welding on the outer ring of the second web plate 4 and the second annular groove 102, and then perform full welding on the inner ring of the second web plate 4 and the hub 2.

[0061] Specifically, in the machining process of the guide wheel, the protrusion amount of one end face of the hub 2 is 6.5 mm, while the protrusion amount of the other end face of the hub 2 is 1 mm. Although both end faces of this form of guide wheel can be machined, due to the different protrusion amounts of the hub 2, when the same tool is used to machine both ends respectively, because the protrusion amount of one end is larger, it is more difficult to machine this end face. The machining process is not only slow, but also prone to tool breakage during the machining process, which greatly increases the labor cost and tool cost of the machining process, and also greatly reduces the production efficiency of the automatic machining line.

[0062] When welding using the above welding steps, on the basis that the end face of the hub 2 protrudes from the end face of the rim 1, the difference in the protrusion amounts of the two end faces of the hub 2 can be reduced, and the consistency of the protrusion of the two end faces of the hub 2 from the end face of the rim 1 can be improved. This can not only ensure the minimum machining allowance on the subsequent automated machining line, avoid the residue of black skin, but also avoid the tool breakage caused by excessive machining allowance, reduce tool loss, and ensure the production efficiency of the automated machining line. For example: after using the above welding steps, the protrusion amount of one end face of the hub 2 becomes 5 mm, while the protrusion amount of the other end becomes 2.5 mm.

[0063] In a possible implementation manner, the first preset angle is less than or equal to the second preset angle.

[0064] When there is a difference between the first preset angle and the second preset angle, the pre-deformation amount can be more significantly improved.

[0065] Specifically, as Figure 3 shown, the angle shown as A is the first preset angle, and the angle shown as B is the second preset angle.

[0066] In a possible implementation manner, the depth of the first annular groove 101 along the axial direction is the first preset depth, the depth of the second annular groove 102 along the axial direction is the second preset depth, and the first preset depth is less than or equal to the second preset depth.

[0067] When there is a difference between the first preset depth and the second preset depth, the pre-deformation amount can be more significantly improved.

[0068] Specifically, as Figure 3 shown, the depth dimension shown as C is the first preset depth, and the depth dimension shown as D is the second preset depth.

[0069] Next, the guide wheel of model 190C will be described in detail:

[0070] In the guide wheel of this model, the range of the first preset angle is from 5 degrees to 7 degrees, preferably 6 degrees, the range of the second preset angle is from 9 degrees to 11 degrees, preferably 10 degrees, the range of the first preset depth is from 16.94 mm to 17.14 mm, preferably 17.04 mm, and the range of the second preset depth is from 19.94 mm to 20.14 mm, preferably 20.04 mm.

[0071] The experimental data of using the above welding method are shown in Table 1 below.

[0072]

[0073] Table 1 Deformation amount test after using specific welding steps

[0074] Here, it should be noted that NG means unqualified and OK means qualified. The perforated side and non-perforated side of the guide wheel represent the two ends of the guide wheel's axis respectively. When the hub 2 is the longest and the rim 1 is the shortest in the 190C model guide wheel, the length difference between the hub 2 and the rim 1 is 4.8 mm. When the protrusion amount at one end is less than 4.8 mm, the protrusion amounts at both ends are greater than 0, that is, the end faces of the perforated side and non-perforated side of the guide wheel can both be machined.

[0075] It should be noted that 4.8 mm does not take into account the increase in the width of the rim after quenching. Its actual width increases by an average of 1.1 mm, with a minimum increase of 0.7 mm and a maximum increase of 1.6 mm. The maximum value of the length difference between the hub 2 and the rim 1 will become 4.1 mm.

[0076] As can be seen from the above table, by adopting the above welding step sequence, the reverse deformation amount generated after heat treatment steps such as quenching is relatively small, all within 1 mm. Adopting the above welding step sequence can effectively ensure that the end faces of the hubs 2 on the perforated side and non-perforated side of the guide wheel both protrude from the end face of the rim 1.

[0077] In a possible implementation manner, after the steps of first welding and fixing the first web plate 3 to the first annular groove 101 and the hub 2 respectively, and then welding and fixing the second web plate 4 to the second annular groove 102 and the hub 2 respectively, the following steps are further included:

[0078] Inductively heat the welded guide wheel with a medium frequency through the heating device 5, and perform quenching on the guide wheel.

[0079] Through the medium frequency quenching step, the strength and wear resistance of the welded guide wheel can be further improved, and the stress condition therein can be improved.

[0080] Among them, the steps of medium frequency quenching are not strictly limited, and the specific steps and quenching parameters of medium frequency quenching can be selected according to the specification size of the guide wheel.

[0081] In a possible implementation manner, the steps of inductively heating the welded guide wheel with a medium frequency through the heating device 5 and performing quenching on the guide wheel include:

[0082] Heat the tread surface of the rim 1 at the end where the first web plate 3 is located of the guide wheel through the heating device 5, and perform the first cooling quenching on the guide wheel;

[0083] Heat the tread surface of the rim 1 at the end where the second web plate 4 is located of the guide wheel through the heating device 5, and perform the second cooling quenching on the guide wheel.

[0084] Through such a quenching step, the difference in the protrusion amount of the two end faces of the hub 2 can be further reduced on the previous basis, improving the consistency of the protrusion of the two end faces of the hub 2 from the end face of the rim 1.

[0085] Specifically, after optimizing the difference in the protrusion amount of the hub 2 by using the above welding steps, although the phenomenon of tool breakage during machining can be greatly reduced, since there is still a large difference in the protrusion amounts at both ends of the hub 2, when machining both ends, the machining efficiency of the end with a larger protrusion amount is still low.

[0086] After adopting the above welding and further using the above quenching sequence, the difference in the protrusion amounts at both ends of the hub 2 can be further optimized. For example, after using the above welding steps, the protrusion amount of one end face of the hub 2 becomes 4 mm, while the protrusion amount of the other end becomes 3.5 mm.

[0087] Next, the guide wheel of model 190C will still be used for detailed description:

[0088] Based on adopting the above welding method, the experimental data of adopting the above quenching steps are shown in Table 2 and Table 3 below.

[0089]

[0090] Table 2 Deformation amount test of one end after adopting a specific welding step

[0091]

[0092] Table 3 Deformation amount test of the other end after adopting a specific welding step

[0093] As can be seen from the above table, after adopting the above welding step sequence and quenching step sequence, the difference in the protrusion amounts on both sides of the hub can be reduced to within the range of 2 mm or less, effectively improving the consistency and efficiency during the machining of different end faces in the machining process of the guide wheel.

[0094] In a possible implementation manner, the hub 2 has a through hole 201 extending axially therein;

[0095] The heating device 5 includes an induction heater 501 and a rotatable positioning assembly 502. The positioning assembly 502 includes an axially positioning rotary tray 5021 and a radially positioning central pin 5022. The axially positioning rotary tray 5021 has three bearing surfaces 5023 spaced 120°, and the bearing surfaces 5023 are used for abutting and cooperating with the end face of the rim 1. The radially positioning central pin 5022 is disposed on the axially positioning rotary tray 5021 and is coaxially disposed with the axially positioning rotary tray 5021. One end of the radially positioning central pin 5022 away from the axially positioning rotary tray 5021 forms a positioning end, and the positioning end is used for plugging and cooperating with the through hole 201 of the hub 2.

[0096] Using the heating device 5 in this form, through the axial positioning of the radial positioning center pin shaft 5022 and the through hole 201, it can ensure that the guide wheel does not have any radial movement in any direction during rotation, stabilize the radial runout of the wheel body tread, and through the end face positioning of the bearing surface 5023 of the axial positioning rotary tray 5021 and the rim 1, it can further reduce the possibility of the guide wheel shaking during rotation, effectively improve the heat uniformity of the guide wheel during rotation, and ensure the consistency and controllability of the further deformation of the guide wheel after heat treatment.

[0097] Specifically, the induction heater 501 is an induction heater.

[0098] In a possible implementation manner,

[0099] The steps of performing medium-frequency induction heating on the welded guide wheel by the heating device 5 and quenching the guide wheel include:

[0100] Heating the tread of the rim 1 at the end where the first web 3 is located by the heating device 5 to 850 - 900 °C, and the heating time range is 145 - 465 S;

[0101] Lower the guide wheel into the quenching water tank for immersion spray quenching, the water spraying time range is 120 - 140 S, the water spraying pressure range is 0.1 - 0.3 MPa, the water spraying flow rate range is 55 - 75 m³ / h, and the final quenching hardness ≥ 51 HRC;

[0102] Heating the tread of the rim 1 at the end where the second web 4 is located by the heating device 5 to 850 - 900 °C, and the heating time range is 145 - 465 S;

[0103] Lower the guide wheel into the quenching water tank for immersion spray quenching, the water spraying time range is 120 - 140 S, the water spraying pressure range is 0.1 - 0.3 MPa, the water spraying flow rate range is 55 - 75 m³ / h, and the final quenching hardness ≥ 51 HRC.

[0104] The quenching step is simple and effective, and can effectively improve the overall structural strength of the guide wheel and the wear resistance of the rim tread.

[0105] In a possible implementation manner, after the steps of performing medium-frequency induction heating on the welded guide wheel by the heating device 5 and quenching the guide wheel, it further includes:

[0106] Performing low-temperature tempering on the guide wheel, the tempering temperature range is 190 - 210 °C, the tempering time range is 1.5 H - 2.5 H, so that the tread hardness of the rim 1 after tempering of the guide wheel is controlled at 48 - 58 HRC.

[0107] While eliminating the internal stress of the guide wheel through the tempering step, the hardness of the rim 1 can also be further adjusted to prevent cracking and improve strength and wear resistance.

[0108] Specifically, the overall rim 1 can be axially divided into three parts: the first tread section 103, the protruding section 104, and the second tread section 105. The first annular groove 101 is located inside the first tread section 103, and the second annular groove 102 is located inside the second tread section 105. After quenching, the metallographic structure of the hardened layer is 3-7 grades. The hardened layer depth of the tread and the side of the boss of the rim 1 is ≥3 mm, and the hardened layer depth at the inner corner formed by the tread and the side of the boss is ≥1 mm.

[0109] Furthermore, it should be noted that Figure 2 only the key steps in the manufacturing method of the guide wheel in this embodiment are listed, and not all steps are listed. The necessary processing steps required in the manufacturing process can also be flexibly inserted according to requirements.

[0110] According to an embodiment of the present invention, on the other hand, a guide wheel is provided, which is manufactured by the above-mentioned guide wheel manufacturing method, and includes: a rim 1, a hub 2, and a first spoke 3 and a second spoke 4. The hub 2 is fixedly connected to the rim 1 through the first spoke 3 and the second spoke 4 respectively.

[0111] Although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for manufacturing a guide wheel, the guide wheel comprising a rim (1), a hub (2), a first spoke plate (3) and a second spoke plate (4), characterized in that: The guide wheel manufacturing method comprises: Bend a portion of the outer ring of the first spoke (3) at a first preset angle, and bend a portion of the outer ring of the second spoke (4) at a second preset angle; A first annular groove (101) is formed on the inner ring of one axial end of the wheel rim (1), and a second annular groove (102) is formed on the inner ring of the other axial end of the wheel rim (1); First, the first spoke plate (3) is respectively welded to the first annular groove (101) and the wheel hub (2) and fixed, and then the second spoke plate (4) is respectively welded to the second annular groove (102) and the wheel hub (2) and fixed; The steps of firstly welding and fixing the first spoke plate (3) to the first annular groove (101) and the wheel hub (2) respectively, and then welding and fixing the second spoke plate (4) to the second annular groove (102) and the wheel hub (2) respectively include: The first spoke plate (3) is fixed to the first annular groove (101) and the wheel hub (2) by spot welding respectively, and the second spoke plate (4) is fixed to the second annular groove (102) and the wheel hub (2) by spot welding respectively; Firstly, the inner ring of the first spoke plate (3) is fully welded to the wheel hub (2), and then the outer ring of the first spoke plate (3) is fully welded to the first annular groove (101); Firstly, the outer ring of the second spoke plate (4) and the second annular groove (102) are fully welded, and then the inner ring of the second spoke plate (4) and the wheel hub (2) are fully welded; After the steps of first welding and fixing the first spoke plate (3) to the first annular groove (101) and the wheel hub (2) respectively, and then welding and fixing the second spoke plate (4) to the second annular groove (102) and the wheel hub (2) respectively, the method further comprises: The guide wheel that has been welded is subjected to medium frequency induction heating by a heating device (5), and the guide wheel is quenched.

2. The guide wheel manufacturing method according to claim 1, characterized in that: The first preset angle is less than or equal to the second preset angle.

3. The guide wheel manufacturing method according to claim 2, characterized in that: The depth of the first annular groove (101) along the axial direction is a first preset depth, the depth of the second annular groove (102) along the axial direction is a second preset depth, and the first preset depth is less than or equal to the second preset depth.

4. The guide wheel manufacturing method according to claim 2, characterized in that: The steps of performing medium frequency induction heating on the welded guide wheel by means of a heating device (5) and quenching the guide wheel include: The rim tread of one end of the rim (1) of the guide wheel where the first web (3) is located is heated by a heating device (5), and the guide wheel is subjected to a first cooling and quenching process; The tread surface of one end of the rim (1) of the guide wheel where the second web (4) is located is heated by a heating device (5), and the guide wheel is subjected to a second cooling and quenching.

5. The guide wheel manufacturing method according to claim 2, characterized in that: The hub (2) has a through hole (201) extending in the axial direction inside; The heating device (5) comprises an induction heater (501) and a rotatable positioning assembly (502); the positioning assembly (502) comprises an axial positioning rotary tray (5021) and a radial positioning center pin (5022); the axial positioning rotary tray (5021) has three bearing surfaces (5023) spaced 120 degrees apart; the bearing surfaces (5023) are used to abut against the end surfaces of the wheel rim (1); the radial positioning center pin (5022) is arranged on the axial positioning rotary tray (5021) and is coaxially arranged with the axial positioning rotary tray (5021); the radial positioning center pin (5022) is used to be plugged into and fitted with the through hole (201) of the wheel hub (2).

6. The guide wheel manufacturing method according to claim 4, characterized in that: The steps of performing medium frequency induction heating on the welded guide wheel by means of a heating device (5) and quenching the guide wheel include: The tread surface of the rim (1) at the end where the first web (3) is located is heated to 850-900° C. by means of a heating device (5), with the heating time ranging from 145 to 465 seconds; The guide wheel is sunk into the quenching water tank for immersion spray quenching, the spraying time range is 120-140S, the spraying pressure range is 0.1-0.3MPa, the spraying flow range is 55-75m³ / h, and the final quenching hardness is ≥51HRC; The tread surface of the rim (1) at the end where the second web (4) is located is heated to 850-900° C. by means of a heating device (5), with the heating time ranging from 145 to 465 seconds; The guide wheel is sunk into the quenching water tank for immersion spray quenching, the spraying time range is 120-140S, the spraying pressure range is 0.1-0.3MPa, the spraying flow range is 55-75m³ / h, and the final quenching hardness is ≥51HRC.

7. The guide wheel manufacturing method according to claim 4, characterized in that: After the step of performing medium frequency induction heating on the welded guide wheel by the heating device (5) and quenching the guide wheel, the method further comprises: The guide wheel is subjected to low temperature tempering, the tempering temperature range is 190-210° C., and the tempering time range is 1.5 hours-2.5 hours, so that the tread hardness of the wheel rim (1) after the guide wheel is tempered is controlled to be 48-58 HRC.

8. A guide wheel manufactured by the guide wheel manufacturing method according to any one of claims 1 to 7, characterized in that: include: A wheel rim (1), a wheel hub (2), a first spoke plate (3) and a second spoke plate (4), wherein the wheel hub (2) is fixedly connected to the wheel rim (1) via the first spoke plate (3) and the second spoke plate (4), respectively.

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