Elevator car roof wheel and forming die

Abstract

The invention relates to an elevator car roof wheel and a forming die. An elevator car roof wheel comprises a cylinder and a plurality of arc-shaped plates of the same structure. A plurality of rib plates are fixed on the outer wall of the cylinder and are radially fixed on the outer wall of the cylinder; the arc-shaped plate is formed by bending a corrugated plate with grooves, and a plurality of channels are formed in the outer side of the arc-shaped plate; the arc-shaped plates are sequentially connected end to end and fixed to the rib plate, the arc-shaped plates are connected end to end to just form a circle, the corresponding channels in the adjacent arc-shaped plates are connected, and the channels in the arc-shaped plates are connected to form a plurality of annular grooves. According to the elevator car roof wheel and the forming die, the car roof wheel is light in weight, machining is not needed in the machining process when the elevator car roof wheel is manufactured through the forming die, the theoretical material utilization rate can reach 100%, and the manufacturing cost is greatly saved.

Description

Technical Field

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

[0002] At present, the molding technology of the car top wheel 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 an elevator car top wheel, which is light in weight, does not require machining during the processing process, is easy to process, can effectively improve the processing efficiency of the car top wheel, has no material loss, and greatly saves manufacturing costs.

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

[0006] An elevator car top wheel, which is special in that:

[0007] It includes a cylinder and a plurality of arc-shaped plates with the same structure;

[0008] A plurality of ribs are fixed to the outer wall of the cylinder, and the ribs are fixed to the outer wall of the cylinder in a radial shape;

[0009] The arc-shaped plate is formed by bending a grooved corrugated plate, and a plurality of grooves are formed on the outer side of the arc-shaped plate;

[0010] A plurality of arc plates are connected end to end in sequence and fixed on the rib plate, and the arc plates are connected end to end to form a circle, and the corresponding grooves on adjacent arc plates are connected, and the grooves on the arc plates are connected to form a plurality of annular grooves.

[0011] Furthermore, the arc-shaped plate is formed by bending a grooved corrugated plate through a mold.

[0012] Furthermore, the above-mentioned corrugated plate with grooves is formed by rolling the metal plate through a plate rolling machine.

[0013] Furthermore, the ribs are fixed to the outer wall of the cylinder by welding, so that the ribs are fixed to the outer wall of the cylinder in a radial shape.

[0014] Furthermore, 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.

[0015] Furthermore, 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.

[0016] Furthermore, there are three arc-shaped plates, and the three curved plates are connected end to end to form a circle.

[0017] Furthermore, the arc-shaped plates are welded end to end in sequence to form a circular plate, the inner wall of the circular plate is welded to the outer end of the rib plate, and the connection between adjacent arc-shaped plates corresponds to the outer end of a rib plate.

[0018] In addition, the present invention also provides a molding die, which is special in that:

[0019] The mold comprises a rolling wheel and an arc-shaped rolling plate. The outer wall of the rolling wheel and the inner side of the arc-shaped rolling plate are both provided with grooves. The rolling wheel and the arc-shaped rolling plate bend the corrugated plate with grooves into an arc-shaped plate.

[0020] Furthermore, the arc length of the arc-shaped rolled plate is greater than the length of the corrugated plate with grooves.

[0021] Advantages of the present invention:

[0022] The car top wheel proposed in the present invention 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; the car top wheel is light, which can make the installation and maintenance of the car top wheel more convenient and simple. 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 the corrugated plate forming process of the elevator car top wheel proposed by the present invention;

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

[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;

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

[0028] Figure 6is 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 an elevator car top wheel, see Figure 5 , including a cylinder 5 and a plurality of arc-shaped plates 3 with the same structure; a plurality of rib plates 4 are fixed to the outer wall of the cylinder 5, and the rib plates 4 are radially fixed to the outer wall of the cylinder 5; the arc-shaped plate 3 is formed by bending a corrugated plate 2 with a groove, and a plurality of grooves are formed on the outer side of the arc-shaped plate 3; a plurality of arc-shaped plates 3 are fixed on the rib plate 4 end to end in sequence, and a plurality of arc-shaped plates 3 are connected end to end to form a circle, and the corresponding grooves on adjacent arc-shaped plates 3 are connected, and the grooves on the plurality of arc-shaped plates 3 are connected to form a plurality of annular grooves.

[0038] Specifically, see Figure 2 The grooved corrugated plate 2 is formed by rolling a metal plate blank through a plate rolling machine 6. Figure 3The arc plate 3 is formed by bending the grooved corrugated plate 2 through a specific forming die.

[0039] Specifically, 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.

[0040] Specifically, see Figure 4 Six ribs 4 are welded to the outer wall of the cylinder 5, so that the ribs 4 are fixed radially to the outer wall of the cylinder 5. There are three arc-shaped plates 3, and the three curved plates 3 are connected end to end to form a circle. The three arc-shaped plates 3 are welded end to end in sequence to form a circular plate, and the inner wall of the circular plate is welded to the outer end of the rib plate 4, and the connection between adjacent arc-shaped plates 3 corresponds to the outer end of a certain rib plate 4.

[0041] The present invention provides a molding die, see Figure 3 The mold includes a rolling wheel 7 and an arc-shaped rolling plate 8. Grooves are provided on the outer wall of the rolling wheel 7 and the inner side of the arc-shaped rolling plate 8. The arc length of the arc-shaped rolling plate 8 is greater than the length of the corrugated plate 2 with grooves.

[0042] When the forming mold is working: the rolling wheel 7 and the arc-shaped rolling plate 8 are separated first, and the corrugated plate 2 with grooves to be bent is placed on the arc-shaped rolling plate 8, so that the rolling wheel 7 is pressed downward toward the arc-shaped rolling plate 8, and the rolling wheel 7 and the arc-shaped rolling plate 8 bend the corrugated plate 2 with grooves into an arc-shaped plate 3.

[0043] By adopting the molding die of the present invention and using metal materials such as Q235, a car top wheel with a diameter of 400 mm is manufactured, which weighs only about 13 kg. The car top wheel is light, which makes the installation and maintenance of the car top wheel 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.

[0044] The corrugated plate forming process and the curved plate forming process of the present invention have been simulated and proved to be feasible.

[0045] I numerically simulate the corrugated board forming process:

[0046] 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.

[0047] 2. Simulation parameter setting

[0048] 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;

[0049] 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.

[0050] 3. Analysis of numerical simulation results

[0051] 3.1 Simulation results at a rotation speed of 2.62 rad / s

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 3.2 Simulation results at a rotation speed of 0.95 rad / s

[0057] 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.

[0058] 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.

[0059] 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 5 N, 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.

[0060] D = 300, n = 0.95rad / s, corrugated plate thickness 2mm, width w500mm, Y-axis load 3.36e6N, forming wheel torque peak 1.5e8N*mm, formed plate length 198.52mm, thickest part 1.97mm, thinnest part 0.94mm, 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.

[0061] D = 300, n = 0.95rad / s, corrugated plate thickness 2.5mm, w500mm, the numerical simulation results show that the average Y-axis load under stable processing state is 1.96*10 6 N, the peak torque of the forming wheel is 1.05*10 5N*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.

[0062] D = 300, n = 0.95rad / s, corrugated plate thickness 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.

[0063] 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.

[0064] II. Perform finite element analysis on the process of bending the corrugated sheet into a specific curved sheet in step 3

[0065] Simufact Forming 2022 software was used for this simulation, and the preliminary simulation parameters are shown in the following table:

[0066]

[0067]

[0068] 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:

[0069] (1) 3mm plate setting

[0070] 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:

[0071] 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.

[0072] 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.

[0073] The reason for the change in slope is that the plate is divided into three different stress stages during the bending process:

[0074] (1) In the first stage, the upper die bends the sheet through the center point as follows Fig.10 shown.

[0075] (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.

[0076] (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.

[0077] 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. An elevator car top wheel, which is special in that: It comprises a cylinder (5) and a plurality of arc-shaped plates (3) with the same structure; A plurality of ribs (4) are fixed to the outer wall of the cylinder (5), and the ribs (4) are fixed to the outer wall of the cylinder (5) in a radial shape; The arc-shaped plate (3) is formed by bending a grooved corrugated plate (2), and a plurality of grooves are formed on the outer side of the arc-shaped plate (3); A plurality of arc-shaped plates (3) are connected end to end in sequence and fixed on the rib plate (4); the plurality of arc-shaped plates (3) are connected end to end to form a circle; the corresponding grooves on adjacent arc-shaped plates (3) are connected; and the grooves on the plurality of arc-shaped plates (3) are connected to form a plurality of annular grooves.

2. The elevator car top wheel according to claim 1 is characterized in that: The arc-shaped plate (3) is formed by bending a grooved corrugated plate (2) through a mold.

3. The elevator car top wheel according to claim 2 is characterized in that: The grooved corrugated plate (2) is formed by rolling a metal plate using a plate rolling machine (6).

4. The elevator car top wheel according to claim 3 is characterized in that: 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.

5. The elevator car top wheel according to claim 4 is characterized in that: 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.

6. The elevator car top wheel according to claim 5 is characterized in that: Six rib plates (4) are welded to the outer wall of the cylinder (5), so that the rib plates (4) are fixed to the outer wall of the cylinder (5) in a radial shape.

7. The elevator car top wheel according to claim 6 is characterized in that: The number of the arc-shaped plates (3) is three, and the three arc-shaped plates (3) are bent end to end to form a circle.

8. The elevator car top wheel according to claim 7 is characterized in that: The arc-shaped plates (3) are welded end to end in sequence to form a circular plate, the inner wall of the circular plate is welded to the outer end of the rib plate (4), and the connection point of adjacent arc-shaped plates (3) corresponds to the outer end of a rib plate (4).

9. A molding die, the special features of which are: The mold comprises a rolling wheel (7) and an arc-shaped rolling plate (8), and grooves are provided on the outer wall of the rolling wheel (7) and the inner side of the arc-shaped rolling plate (8). The rolling wheel (7) and the arc-shaped rolling plate (8) bend the corrugated plate (2) with grooves into an arc-shaped plate (3).

10. The elevator car top wheel according to claim 9 is characterized in that: The arc length of the arc-shaped rolled plate (8) is greater than the length of the grooved corrugated plate (2).

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