Elevator car roof wheel forming method

Abstract

The invention relates to an elevator car roof wheel forming method. The method comprises the steps that firstly, a metal blank with the proper width and thickness is cut into metal plates with the proper length; 2, the metal plate is rolled and formed into a corrugated plate with a groove profile; 3, bending the corrugated plate into a specific arc-shaped plate by using a mold with a special shape; 4, a cylinder is taken, a plurality of rib plates are fixed to the outer wall of the cylinder, and the rib plates are fixed to the outer wall of the cylinder in a radial mode; and 5, the bent specific arc-shaped plates are sequentially connected end to end and welded to form a circular plate, then the circular plate is welded to the rib plate, or the bent specific arc-shaped plates are sequentially welded to the rib plate, and the car roof wheel can be manufactured. The car roof wheel obtained through the elevator car roof wheel forming method is light in weight, meanwhile, the theoretical material utilization rate can reach 100%, the material cost is greatly saved, machining is not needed in the whole machining process, and the manufacturing cost is greatly reduced.

Description

Technical Field

[0001] The invention relates to a method for forming an elevator car top wheel. Background Art

[0002] At present, the molding technology of the top wheel of the car mainly adopts the casting-finishing method, that is, firstly a car top wheel blank is obtained by a casting method, and then the final car top wheel is obtained by a machining method. Figure 1 As shown, the car top wheel has a large mass, is inconvenient to install, and consumes a lot of materials.

[0003] For example, for a car top wheel with a diameter of 400mm, the current casting and molding methods require a blank mass of more than 60kg, and the mass of the workpiece after cutting is also more than 50kg. This makes the raw material cost of a single car top wheel of this solution high, and because of the large amount of cutting, the tool loss is also large, which increases the cost of the enterprise from another perspective. Summary of the invention

[0004] In order to solve the problems existing in the above-mentioned background technology, the present invention proposes a method for forming an elevator car top wheel. The car top wheel formed by this method is light in weight. At the same time, the theoretical material utilization rate can reach 100%, which greatly saves material costs. No machining is required in the entire processing process, which greatly reduces the manufacturing cost.

[0005] The technical solution of the present invention to solve the above problems is:

[0006] A method for forming an elevator car top wheel, which is special in that it includes the following steps:

[0007] Step 1, first cut the metal blank with appropriate width and thickness into a metal plate with appropriate length;

[0008] Step 2, rolling the metal plate into a corrugated plate with a groove shape;

[0009] Step 3, using a mold with a special shape to bend the corrugated sheet into a specific curved sheet;

[0010] Step 4, take a cylinder, and fix a plurality of ribs on its outer wall, so that the ribs are fixed on the outer wall of the cylinder in a radial shape;

[0011] Step 5, the bent specific arc plates are welded end to end in sequence to form a circular plate, and then the circular plate is welded to the rib plate, or the bent specific arc plates are welded to the rib plate in sequence to manufacture the car top wheel.

[0012] Furthermore, in the above step 1, the metal plate obtained by cutting the metal blank into a rectangular plate.

[0013] Furthermore, in the above step 2, the metal plate is rolled into a grooved corrugated plate by a plate rolling machine.

[0014] Furthermore, in the above step 3, the mold includes a rolling wheel and an arc-shaped rolling plate, and grooves are provided on the side wall of the rolling wheel and one side of the arc-shaped rolling plate, and the rolling wheel and the arc-shaped rolling plate will be bent into a specific arc-shaped plate.

[0015] Furthermore, in the above step 4, the rib plate is fixed to the outer wall of the cylinder by welding, so that the rib plate is fixed to the outer wall of the cylinder in a radial shape.

[0016] Furthermore, in the above step 4, one end of the rib plate is fixed to the outer wall of the cylinder by welding, so that the rib plate is fixed to the outer wall of the cylinder in a radial shape.

[0017] Furthermore, in the above step 4, six ribs are welded to the outer wall of the cylinder so that the ribs are fixed to the outer wall of the cylinder in a radial shape.

[0018] Furthermore, the number of metal plates in the above step 1 is three; in step 3, the three bent arc plates are connected end to end to form a circle.

[0019] Furthermore, in the above step 5, the bent specific arc plates are welded end to end in sequence to form a circular plate, and then the circular plate is welded to the rib plate so that the welding seam of the circular plate corresponds to the outer end of a rib plate.

[0020] Furthermore, in the above step 5, when the bent specific arc-shaped plates are welded to the rib plates in sequence, the two ends and the middle of the arc-shaped plates are welded to a corresponding rib plate respectively.

[0021] Advantages of the present invention:

[0022] The manufacturing process proposed in the present invention has a high material utilization rate, and the manufactured car top wheel is light, which can make the installation and maintenance of the car top wheel more convenient and simple. At the same time, the method does not require machining, which can further save manufacturing costs (tools). The use of three-stage welding can reduce the size of the rolling machine required for the corrugated plate rolling process; each manufacturing process step is a process that can be carried out quickly, which can effectively improve the processing efficiency of the car top wheel. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is the structural diagram of the existing elevator car top wheel;

[0024] Figure 2 It is a schematic diagram of corrugated plate forming in step 2 of the elevator car top wheel forming method proposed by the present invention;

[0025] Figure 3 It is a schematic diagram of the arc plate forming in step 3;

[0026] Figure 4 It is a schematic diagram of obtaining a car top wheel by welding the curved plates to the rib plates in sequence in step 5;

[0027] Figure 5 This is a structural diagram of a car top wheel obtained by using the elevator car top wheel forming method proposed by the present invention;

[0028] Figure 6 is the material rheological curve;

[0029] Figure 7 It is to mesh the corrugated plate;

[0030] Figure 8 This is the result of bending a 3mm sheet;

[0031] Fig. 9 This is the Z-direction force curve of the 3mm plate bending die;

[0032] Fig.10 It is the first stage of bending 3mm sheet metal;

[0033] Fig.11 It is the second stage of 3mm sheet bending;

[0034] Fig.12 It is the third stage of 3mm sheet metal bending.

[0035] Among them, 1-metal plate, 2-corrugated plate, 3-arc plate, 4-rib plate, 5-cylinder, 6-plate rolling machine, 7-roller pressing wheel, 8-roller pressing plate. DETAILED DESCRIPTION

[0036] In order to make the purpose, 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 in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention.

[0037] The present invention provides a method for forming an elevator car top wheel, comprising the following steps:

[0038] Step 1: Cut a metal blank with appropriate width and thickness into a metal plate 1 with appropriate length.

[0039] Step 2, rolling the metal plate 1 into a corrugated plate 2 with a groove, which is specifically as follows: Figure 2According to the required groove shape requirements, a metal plate 1 with a length of 1 / 3 of the required elevator car top wheel circumference is rolled into a corrugated plate 2 with a rope pulley groove at one time using a plate rolling machine 6.

[0040] Step 3, see Figure 3 The corrugated plate 2 is bent into a specific arc-shaped plate 3 with a groove using a mold with a special shape.

[0041] Step 4, see Figure 4 , take a cylinder 5, and fix a plurality of ribs 4 on its outer wall, so that the ribs 4 are fixed on the outer wall of the cylinder 5 in a radial shape.

[0042] Step 5, the bent specific arc plates 3 are welded end to end in sequence to form a circular plate, and then the circular plate is welded to the rib plate 4; or, see Figure 4 and Figure 5 The car top wheel can be manufactured by welding the bent specific arc plate 3 to the rib plate 4 in sequence.

[0043] Specifically, the metal plate 1 obtained by cutting the metal blank in the above step 1 is a rectangular plate with appropriate width, thickness and length.

[0044] Specifically, in the above step 3, the mold includes a rolling wheel 7 and an arc-shaped rolling plate 8, and grooves are provided on the side wall of the rolling wheel 7 and one side of the arc-shaped rolling plate 8, which match the grooves on the corrugated plate 2. The rolling wheel 7 and the arc-shaped rolling plate 8 bend the corrugated plate 2 into a specific arc-shaped plate 3.

[0045] Specifically, in the above step 4, see Figure 4 The rib plate 4 is fixed to the outer wall of the cylinder 5 by welding, so that the rib plate 4 is fixed to the outer wall of the cylinder 5 in a radial shape.

[0046] Specifically, in the above step 4, see Figure 4 One end of the rib plate 4 is fixed to the outer wall of the cylinder 5 by welding, so that the rib plate 4 is fixed to the outer wall of the cylinder 5 in a radial shape.

[0047] Specifically, in the above step 4, see Figure 4 Six ribs 4 are welded to the outer wall of the cylinder 5 so that the ribs 4 are fixed to the outer wall of the cylinder 5 in a radial shape.

[0048] Specifically, the number of metal plates 1 in the above step 1 is three; in step 3, the three bent arc plates 3 are connected end to end to form a circle.

[0049] Specifically, in the above step 5, the bent specific arc plates 3 are welded end to end in sequence to form a circular plate, and then the circular plate is welded to the rib plate 4 so that the welding seam of the circular plate corresponds to the outer end of a rib plate 4.

[0050] Specifically, in the above step 5, see Figure 4 When the bent specific arc plate 3 is welded to the rib plate 4 in sequence, the two ends and the middle of the arc plate 3 are welded to a corresponding rib plate 4 respectively.

[0051] By adopting the molding method of the present invention and using metal materials such as Q235, a car top wheel with a diameter of 400 mm is manufactured, which has a mass of only about 13 kg. The car top wheel is light, and the installation and maintenance of the car top wheel can be made more convenient and simple. At the same time, the theoretical material utilization rate can reach 100%, which greatly saves material costs. No machining is required in the entire processing process, which greatly reduces the manufacturing cost.

[0052] All process flows of the present invention have been simulated and proved to be feasible.

[0053] I numerically simulate the corrugated sheet forming process in step 2:

[0054] 1. Design the rolling die and related process parameters according to the known parameters, conduct numerical simulation on the corrugated plate forming process, determine the radial load of the forming wheel, the torque of the forming wheel, the change of the plate length before and after forming, and the size of the wave structure of the plate after forming. Through the results of numerical simulation, evaluate the feasibility of the forming process and select supporting equipment for rolling test.

[0055] 2. Simulation parameter setting

[0056] The process of corrugated board with three thicknesses of 2mm, 2.5mm and 3mm was simulated with a billet width of 100mm and a rotation speed of 2.62rad / s and 0.95rad / s;

[0057] The process of corrugated plates with three thicknesses of 2mm, 2.5mm and 3mm was simulated with a billet width of 500mm and a rotation speed of 0.95rad / s.

[0058] 3. Analysis of numerical simulation results

[0059] 3.1 Simulation results at a rotation speed of 2.62 rad / s

[0060] D = 300, n = 2.62rad / s, corrugated plate thickness 2mm, numerical simulation results show that the average Y-axis load under stable processing state is 1.8*10 6 N, the peak torque of the forming wheel is 5.33*10 4 N*m, the length of the plate after forming increases by 23.88mm compared with that before forming, the thickest part of the formed corrugated plate is 2.05mm, and the thinnest part is 0.94mm. The forming process has a good effect and the wave structure is stable.

[0061] D = 300, n = 2.62rad / s, corrugated plate thickness 2.5mm, numerical simulation results show that the average Y-axis load under stable processing state is 9.69*10 5 N, the peak torque of the forming wheel is 2.29*10 4 N*m, the length of the plate after forming is 3.06mm shorter than that before forming, the thickest part of the formed corrugated plate is 2.48mm, and the thinnest part is 1.2mm. The forming process effect is good and the wave structure is stable.

[0062] D = 300, n = 2.62rad / s, corrugated plate thickness 3mm, numerical simulation results show that the average Y-axis load under stable processing state is 8.91*10 5 N, the peak torque of the forming wheel is 1.67*10 4 N*m, the length of the plate after forming is 3.06mm shorter than that before forming, the thickest part of the formed corrugated plate is 2.96mm, and the thinnest part is 1.63mm. The forming process effect is good and the wave structure is stable.

[0063] Summary: By comparing the three groups of numerical simulation results, it can be seen that the thickness of the blank has little effect on the load during the forming process. The change in the length of the first group does not conform to the objective law, and the difference with the other two groups is large. Its length change has no reference value.

[0064] 3.2 Simulation results at a rotation speed of 0.95 rad / s

[0065] D = 300, n = 0.95rad / s, corrugated plate thickness 2mm, numerical simulation results show that the average Y-axis load under stable processing state is 1.9*10 6 N, the peak torque of the forming wheel is 6.62*10 4 N*m, the length of the plate after forming is 22.13mm longer than that before forming, the thickest part of the formed corrugated plate is 2.04mm, and the thinnest part is 0.88mm. The forming process effect is good and the wave structure is stable.

[0066] D = 300, n = 0.95rad / s, corrugated plate thickness 2.5mm, numerical simulation results show that the average Y-axis load under stable processing state is 9.02*10 5 N, the peak torque of the forming wheel is 2.33*10 4 N*m, the length of the plate after forming is shortened by 3.79 compared with that before forming, the thickest part of the formed corrugated plate is 2.48mm and the thinnest part is 1.23mm, the forming process effect is good and the wave structure is stable.

[0067] D = 300, n = 0.95rad / s, corrugated plate thickness 3mm, numerical simulation results show that the average Y-axis load under stable processing state is 7*10 5N, the peak torque of the forming wheel is 2.18*10 4 N*m, the length of the plate after forming is 1.56mm shorter than that before forming, the thickest part of the formed corrugated plate is 2.95mm, and the thinnest part is 1.39mm. The forming process effect is good and the wave structure is stable.

[0068] D = 300, n = 0.95rad / s, 2mm, width w500mm, Y-axis load 3.36e6N, forming wheel torque peak 1.5e8N*mm, the length of the formed plate is 198.52mm, the thickest part is 1.97mm, and the thinnest part is 0.94mm. The numerical simulation results show that the average Y-axis load under stable processing state is 3.36*10 6 N, the peak torque of the forming wheel is 1.5*10 5 N*m, the length of the plate after forming is 1.48mm shorter than that before forming, the thickest part of the formed corrugated plate is 1.97mm, and the thinnest part is 1.39mm. The forming process effect is good and the wave structure is stable.

[0069] D = 300, n = 0.95rad / s, 2.5mm, w500mm, the numerical simulation results show that the average load in the Y direction under the stable processing state is 1.96*10 6 N, the peak torque of the forming wheel is 1.05*10 5 N*m, the length of the plate after forming is 1mm shorter than that before forming, the thickest part of the formed corrugated plate is 2.47mm, and the thinnest part is 0.86mm. The forming process effect is good and the wave structure is stable.

[0070] D = 300, n = 0.95rad / s, 2.5mm, w500mm, the numerical simulation results show that the average Y-axis load under stable processing state is 2.76*10 6 N, the peak torque of the forming wheel is 1.02*10 5 N*m, the length of the plate after forming is 3.69mm longer than that before forming, the thickest part of the formed corrugated plate is 3.1mm and the thinnest part is 1.44mm. The forming process has a good effect and the wave structure is stable.

[0071] Summary: By comparing the three groups of numerical simulation results, it is confirmed that the thickness of the blank has little effect on the load during the forming process. The changes in the length of the first and third groups of plates do not conform to the objective law, and their length changes have no reference value. By comparing the numerical simulation results of 100mm and 500mm plate widths within the same group, it can be seen that the processing load has a nonlinear relationship with the plate width. When the width difference is 5 times, the load difference is only 2 to 3 times.

[0072] II. Perform finite element analysis on the process of bending the corrugated sheet into a specific curved sheet in step 3

[0073] Simufact Forming 2022 software was used for this simulation, and the preliminary simulation parameters are shown in the following table:

[0074] 1 2 3 Corrugated board thickness 3 2 2.5 Corrugated board length 418.67 418.67 418.67 Material Q235 Q235 Q235 Pressing time 10 10 10 Circumference angle 120 120 120

[0075] The corrugated plate and the roller pressing wheel 7 and the arc-shaped roller pressing plate 8 are arranged in accordance with Figure 3 The roller 7 and the arc-shaped roller plate 8 are placed in the same way as in the middle left figure, where the roller 7 and the arc-shaped roller plate 8 are established completely according to the relevant parameters of the corrugated plate model; the plate in this simulation uses Q235 steel as the material, and the roller 7 and the arc-shaped roller plate 8 are rigid bodies, in order to reduce the calculation cost and improve the calculation efficiency. The selected material rheological curve is as follows Figure 6 As shown. During the simulation, there is friction between the corrugated plate and the roller 7 and the arc roller plate 8, with a friction coefficient of 0.12, without any binding relationship, and all simulation temperatures are set to room temperature. The mesh, feed rate, etc. of each group of models under different pipe diameters and wall thicknesses are set as follows:

[0076] (1) 3mm plate setting

[0077] Divide the plate into grids. When the plate length is 418.67 mm and the plate thickness is 3 mm, the grid division is as follows: Figure 7 As shown, the number of grids is about 408037:

[0078] Here the boundary conditions are set as the lower die is fixed, the upper die descends at a speed of 9.3 mm per second for 10 seconds at the point where it is tangent to the plate, forming a distance of 93 mm, then decelerates to a stop and rises to its original position within 1 second, and the contact between the blank and the die is set as contact with friction.

[0079] The simulation results are as follows Figure 8 As shown, the blank rebounds after being pressed down. The die pressure curve during the bending process is as follows: Fig. 9 As shown, the maximum downward force is 57kN, and the slope of the pressure curve changes significantly at 5.2kN and 22.7kN.

[0080] The reason for the change in slope is that the plate is divided into three different stress stages during the bending process:

[0081] (1) In the first stage, the upper die bends the sheet through the center point as follows Fig.10 shown.

[0082] (2) The second stage: the sheet is formed into a V-shaped shape, and the die is bent at two points as follows Fig.11 shown.

[0083] (3) The third stage: The sheet contacts the lower die and enters the downward pressing stage similar to plastic surgery, as follows Fig.12 shown.

[0084] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art can still adjust the technical solutions described in the above embodiments or replace some of the technical features by equivalents. Therefore, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention is also intended to include these modifications and variations.

Claims

1. A method for forming an elevator car top wheel, which is special in that it includes the following steps: Step 1, cutting a metal blank into a metal plate (1); Step 2, rolling the metal plate (1) into a corrugated plate (2) with grooves; Step 3, using a mold to bend the corrugated plate (2) into an arc-shaped plate (3); Step 4, take a cylinder (5), fix a plurality of ribs (4) on the outer wall of the cylinder, and make the ribs (4) be fixed on the outer wall of the cylinder (5) in a radial shape; Step 5, the bent arc plates (3) are welded end to end in sequence to form a circular plate, and then the circular plate is welded to the rib plate (4), or the bent arc plates (3) are welded to the rib plate (4) in sequence, so as to manufacture the car top wheel.

2. The elevator car top wheel forming method according to claim 1 is characterized in that: In the step 1, the metal plate (1) obtained by cutting the metal blank into a rectangular plate.

3. The elevator car top wheel forming method according to claim 2 is characterized in that: In the step 2, the metal plate (1) is rolled into a grooved corrugated plate (2) by a plate rolling machine (6).

4. The elevator car top wheel forming method according to claim 3 is characterized in that: In step 3, the mold includes a rolling wheel (7) and an arc-shaped rolling plate (8), and grooves are provided on the side wall of the rolling wheel (7) and one side of the arc-shaped rolling plate (8). The rolling wheel (7) and the arc-shaped rolling plate (8) bend the corrugated plate (2) into an arc-shaped plate (3).

5. The elevator car top wheel forming method according to claim 4 is characterized in that: In the step 4, the rib plate (4) is fixed to the outer wall of the cylinder (5) by welding, so that the rib plate (4) is fixed to the outer wall of the cylinder (5) in a radial shape.

6. The elevator car top wheel forming method according to claim 5 is characterized in that: In the step 4, one end of the rib plate (4) is fixed to the outer wall of the cylinder (5) by welding, so that the rib plate (4) is fixed to the outer wall of the cylinder (5) in a radial shape.

7. The elevator car top wheel forming method according to claim 6 is characterized in that: In the step 4, six ribs (4) are welded to the outer wall of the cylinder (5), so that the ribs (4) are fixed to the outer wall of the cylinder (5) in a radial shape.

8. The elevator car top wheel forming method according to claim 7 is characterized in that: The number of metal plates (1) in step 1 is three; in step 3, the three bent arc-shaped plates (3) are connected end to end to form a circle.

9. The elevator car top wheel forming method according to claim 8 is characterized in that: In step 5, the bent arc plates (3) are welded end to end in sequence to form a circular plate, and then the circular plate is welded to the rib plate (4) so ​​that the welding seam of the circular plate corresponds to the outer end of a rib plate (4).

10. The elevator car top wheel forming method according to claim 8 is characterized in that: In the step 5, when the bent arc plate (3) is welded to the rib plate (4) in sequence, the two ends and the middle of the arc plate (3) are welded to a corresponding rib plate (4) respectively.

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