Method for manufacturing inner container of electric water boiler

Abstract

The invention discloses a method for manufacturing an inner container of an electric water boiler, which is characterized by comprising the following steps of: 1, preparing a bottom cover; the process comprises the following steps: step 1, cutting a top cover and a barrel body; step 2, forming a bottom cover; step 3, forming the top cover; step 4, processing the top cover; and thirteenthly, roll welding is conducted on the bottom cover, the top cover and the top cover blank. The manufacturing process is simple, the labor intensity is low, the qualification rate of the inner container is effectively increased, the manufacturing time is short, and the production cost is low.

Description

Technical Field

[0001] The present invention relates to a manufacturing method for the inner tank of an electric water heater.

Background Art

[0002] An electric water heater is a water heating device that converts electrical energy into heat energy designed to meet the drinking water needs of different people in various environments. Due to its fast heating speed and convenient use, it has been widely used in office places, hotels, restaurants, industrial and mining enterprises, schools, and even households. In the prior art, some inner tanks of electric water heaters are manufactured by stamping, and some are manufactured by welding. However, the above manufacturing methods have complex manufacturing processes and long manufacturing times. Especially for the welding manufacturing method, the welding difficulty is high, and the strength and tightness of the welds cannot be guaranteed, resulting in a low qualification rate of the inner tank and a long manufacturing time for the inner tank, which also makes the production cost of the electric water heater high; and when users use it, the water in the inner tank will produce peculiar smells, which is not conducive to the health and safety of users.

Summary of the Invention

[0003] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a manufacturing method for the inner tank of an electric water heater with a simple manufacturing process, low labor intensity, effectively improving the qualification rate of the inner tank, short manufacturing time, and low production cost.

[0004] The purpose of the present invention is achieved as follows:

[0005] A manufacturing method for the inner tank of an electric water heater, characterized in that the manufacturing steps are as follows:

[0006] Step 1. Blanking of the bottom cover, top cover, and barrel body: Cut or die-cut the blank into corresponding specifications of the bottom cover blank, top cover blank, and barrel body blank, and open a plurality of holes with a preset size on the barrel body blank.

[0007] Step 2. Forming the bottom cover: Press the above bottom cover blank into the shape of the bottom cover, and turn the edge of the bottom cover blank to form a bottom cover flange, and the height of the bottom cover flange is controlled within 6 - 10 mm.

[0008] Step 3. Forming the top cover: Punch a preset size of the tank opening on the top cover blank, turn the edge at the tank opening to form a tank opening flange, and turn the edge of the top cover blank to form a top cover flange. The heights of both the tank opening flange and the top cover flange are controlled within the range of 3 - 8 mm.

[0009] Step 4. Processing the top cover: Press a top cover concave platform and a plurality of top cover counterbores on the edge of the tank opening of the formed top cover blank, and the height of the top cover concave platform is controlled within 3 - 5 mm.

[0010] Step 5. Welding screws to the tank opening of the top cover: Weld top cover screws to a plurality of top cover counterbores of the formed top cover blank by stamping.

[0011] Step 6. Flanging of the barrel body flange: Use a punching machine to press a heating flange on the barrel blank, and punch a barrel body concave platform and a barrel body convex platform on the edge of the heating flange. The heights of the barrel body concave platform and the barrel body convex platform are both controlled within 3 - 5 mm.

[0012] Step 7. Flanging of the barrel body flange: Use a punching machine to turn out the flanging of the heating flange on the barrel blank, and control the height of the flange flanging within 3 - 8 mm.

[0013] Step 8. Bending of the barrel body: Use a bending machine or a die to punch the flanged barrel blank to fold out the preset angle and arc of the barrel body, so that the barrel body forms a circle.

[0014] Step 9. Butt welding of the barrel body: Weld one point at the upper and lower positions of the connection of the bent circular barrel blank. According to the length dimension of the inner liner, positioning welding points can be added in the middle to fix the overlap.

[0015] Step 10. Seam welding of the barrel body: Place the sheet material of the barrel blank that has been butt - welded and bent into shape on a seam welding machine, adjust the welding parameters, and perform seam welding operations to weld the entire length of the overlap.

[0016] Step 11. Welding of the nozzle: Weld the nozzle at the hole on the barrel blank after seam welding.

[0017] Step 12. Welding of the flange screw: Weld the flange screw on the barrel blank with the nozzle welded.

[0018] Step 13. Seam welding of the bottom cover and the top cover with the top cover blank: Align the processed bottom cover blank and top cover blank with the above - mentioned barrel blank flush, fix them with spot welding, and then perform seam welding for one week on a seam welding machine to complete the manufacturing of the inner liner.

[0019] A manufacturing method of an electric water heater inner liner as described above, characterized in that a sealing ring is provided in the concave platform of the top cover, and a sealing cover is provided above the sealing ring.

[0020] A manufacturing method of an electric water heater inner liner as described above, characterized in that in Step 5, the welding of the top cover blank and the top cover screw uses capacitor energy - storage welding. Align the electrode tip vertically with the center of the head of the top cover screw to avoid offset resulting in poor welding. After pressing the welding machine, release it quickly to avoid continuous discharge burning through the sheet material. Check whether the top cover screw is stable after welding.

[0021] A manufacturing method of an electric water heater inner liner as described above, characterized in that in Step 11, the welding of the nozzle on the barrel blank uses a tungsten - inert - gas welding machine. Place the nozzle correctly at the hole of the barrel blank and perform tungsten - inert - gas welding from the inside of the barrel blank.

[0022] A manufacturing method for the inner tank of an electric water heater as described above, characterized in that in step twelve, the welding of the barrel blank and the flange screw uses capacitor energy storage welding. The electrode tip is vertically aligned with the center of the flange screw head to avoid virtual welding caused by deviation. After pressing the welding machine, quickly release it to avoid continuous discharge burning through the plate. After welding, check whether the flange screw is stable.

[0023] A manufacturing method for the inner tank of an electric water heater as described above, characterized in that in step five, the capacitance of the capacitor energy storage welding is: 500 - 1000 μF; the charging voltage is: 100 - 200 V; the discharge time is: 0.2 - 0.5 ms; the electrode pressure is: 2 - 4 MPa.

[0024] A manufacturing method for the inner tank of an electric water heater as described above, characterized in that in step ten, the welding alternating current of the seam welder is: 10 - 20 kA; the welding voltage is 1.8 - 2.8 V; the welding speed is: 3 - 5 m / min; the electrode pressure is: 15 - 22 MPa; the pulse frequency is: 0 - 200 Hz.

[0025] A manufacturing method for the inner tank of an electric water heater as described above, characterized in that in step eleven, the welding current of the seam welding is: 25 - 35 A; the weld width is: 3 - 4 mm; the argon gas flow rate is 8 - 10 L / min; arc extinguishing treatment: fill the crater to prevent cracks.

[0026] A manufacturing method for the inner tank of an electric water heater as described above, characterized in that in step twelve, capacitor energy storage welding is used, and its capacitance is: 500 - 1000 μF; the charging voltage is: 100 - 200 V; the discharge time is: 0.2 - 0.5 ms; the electrode pressure is: 2 - 4 MPa.

[0027] A manufacturing method for the inner tank of an electric water heater as described above, characterized in that in step twelve, the welding alternating current of the seam welder is: 10 - 20 kA; the welding voltage is 1.8 - 2.8 V; the welding speed is 3 - 5 m / min; the electrode pressure is 15 - 22 MPa; the pulse frequency is 50 - 200 Hz.

[0028] The beneficial effects of the present invention are:

[0029] The manufacturing process of the present invention is simple, the labor intensity of workers is low, the qualified rate of the inner tank is effectively improved, the manufacturing time is short, and the production cost is low.

Description of the Drawings

[0030] Figure 1 is a perspective view of the present invention;

[0031] Figure 2 is a front view of the present invention;

[0032] Figure 3 is Figure 2Cross-sectional view A-A;

[0033] Figure 4 is the three-dimensional view of the barrel body of the present invention;

[0034] Figure 5 is the three-dimensional view of the top cover of the present invention;

[0035] Figure 6 is the three-dimensional view of the top cover of the present invention;

[0036] Figure 7 is the three-dimensional view of the bottom cover of the present invention;

[0037] Figure 8 is the three-dimensional view of the inner tank of the present invention after installing the sealing cover;

[0038] Figure 9 is Figure 8 exploded view.

Detailed implementation manners

[0039] The present invention will be further described below in conjunction with the accompanying drawings:

[0040] A manufacturing method for the inner tank of an electric water heater, and its manufacturing steps are as follows:

[0041] Step 1. Blanking for the bottom cover 1, top cover 2 and barrel body 3: Cut or die-cut the blank to obtain the bottom cover blank, top cover blank and barrel body blank of corresponding specifications, and open a plurality of holes 30 of a preset size on the barrel body blank;

[0042] Step 2. Forming the bottom cover: Press the above-mentioned bottom cover blank into the shape of the bottom cover 1, turn up the periphery of the bottom cover blank to form the bottom cover flange 11, and control the height of the bottom cover flange 11 within the range of 6-10 mm, so as to complete the forming of the bottom cover 1;

[0043] Step 3. Forming the top cover: Punch out a bile opening 21 of a preset size on the top cover blank, turn up the edge at the bile opening 21 to form a bile opening flange 210, and turn up the periphery of the top cover blank to form a top cover flange 22. The heights of both the bile opening flange 210 and the top cover flange 22 are controlled within the range of 3-8 mm;

[0044] Step 4. Processing the top cover: Press out a top cover concave platform 23 and a plurality of top cover countersunk holes 24 on the edge of the bile opening 21 of the formed top cover blank, and control the height of the top cover concave platform 23 within the range of 3-5 mm to complete the processing of the top cover 2;

[0045] Step 5. Welding the top cover bile opening screw: Weld the top cover screw 25 at the top cover countersunk hole 24 of the stamping-formed top cover blank;

[0046] Step 6. Flanging of the barrel body flange: Use a punching machine to press out the heated flange opening 31 on the barrel body blank, and punch out the barrel body concave platform 32 and the barrel body convex platform 33 at the edge of the heated flange opening 31. The heights of both the barrel body concave platform 32 and the barrel body convex platform 33 are controlled within the range of 3 - 5 mm;

[0047] Step 7. Flanging of the barrel body flange: Use a punching machine to turn out the flanged edge 34 of the heated flange opening on the barrel body blank. The height of the flanged edge 34 of the flange opening is controlled within the range of 3 - 8 mm;

[0048] Step 8. Bending of the barrel body: Use a bending machine or a die to punch the flanged barrel body blank to fold out the preset angle and arc of the barrel body, so that the barrel body forms a circle;

[0049] Step 9. Butt welding of the barrel body: Weld one point at each of the upper and lower positions of the connection of the bent circular barrel body blank. Depending on the length dimension of the inner liner, positioning welding points can be added in the middle to fix the overlapping edge;

[0050] Step 10. Seam welding of the barrel body: Place the sheet material of the barrel body blank that has been butt welded and bent into shape on a seam welding machine, adjust the welding parameters, and perform seam welding operations to weld the entire length of the overlapping edge;

[0051] Step 11. Welding of the nozzle: Weld the nozzle 35 at the hole on the barrel body blank after seam welding;

[0052] Step 12. Welding of the flange screw: Weld the flange screw 36 on the barrel body blank with the nozzle welded;

[0053] Step 13. Seam welding of the bottom cover and the top cover with the top cover blank: Align the processed and formed bottom cover blank and top cover blank with the above barrel body blank flush, fix them with spot welding, and then perform seam welding for one week on a seam welding machine to complete the manufacturing of the inner liner.

[0054] In the present invention, a sealing ring 4 is provided in the concave platform 23 of the top cover. A sealing cover 5 is provided above the sealing ring 4. The sealing cover 5 is fixed with the top cover screw 25. The sealing cover 5 is provided with a sealing cover groove 51 that matches the flanged edge of the top cover.

[0055] In step 5 of the present invention, the welding of the top cover blank and the top cover screw adopts capacitor energy storage welding. Vertically align the tip of the electrode with the center of the head of the top cover screw to avoid virtual welding caused by deviation. After pressing the welding machine, quickly release it to avoid continuous discharge from burning through the sheet material. Check whether the top cover screw is stable after welding.

[0056] In step 11 of the present invention, the barrel body blank is welded with the nozzle using a tungsten inert gas welding machine. Place the nozzle correctly at the hole of the barrel body blank and perform tungsten inert gas welding from inside the barrel body blank.

[0057] In step twelve of the present invention, the welding of the barrel blank and the flange screw uses capacitor energy storage welding. Align the electrode tip vertically with the center of the flange screw head to avoid offset resulting in false welding. Press the welding machine and then quickly release it to avoid continuous discharge burning through the plate. After welding, check whether the flange screw is stable.

[0058] In step five of the present invention, the capacitance of the capacitor energy storage welding is: 500 - 1000 μF; the charging voltage is: 100 - 200 V; the discharge time is: 0.2 - 0.5 ms; the electrode pressure is: 2 - 4 MPa.

[0059] In step ten of the present invention, the alternating current for seam welding of the seam welder is: 10 - 20 kA; the welding voltage is 1.8 - 2.8 V; the welding speed is: 3 - 5 m / min; the electrode pressure is: 15 - 22 MPa; the pulse frequency is: 0 - 200 Hz.

[0060] In step eleven of the present invention, the welding current for seam welding is: 25 - 35 A; the weld width is: 3 - 4 mm; the argon flow rate is 8 - 10 L / min; arc extinguishing treatment: fill the crater to prevent cracks.

[0061] In step twelve of the present invention, capacitor energy storage welding is used, and its capacitance is: 500 - 1000 μF; the charging voltage is: 100 - 200 V; the discharge time is: 0.2 - 0.5 ms; the electrode pressure is: 2 - 4 MPa.

[0062] In step twelve of the present invention, the alternating current for seam welding of the seam welder is: 10 - 20 kA; the welding voltage is 1.8 - 2.8 V; the welding speed is 3 - 5 m / min; the electrode pressure is 15 - 22 MPa; the pulse frequency is 50 - 200 Hz.

Claims

1. A manufacturing method of an inner container of an electric water heater, characterized in that The manufacturing steps are as follows: Step 1. Blanking of the bottom cover, top cover and barrel body: Cut or blank the corresponding specifications of the bottom cover blank, top cover blank and barrel body blank from the blank, and open a plurality of holes with a preset size on the barrel body blank; Step 2. Forming of the bottom cover: Press the above bottom cover blank into the shape of the bottom cover, turn over the periphery of the bottom cover blank to form a bottom cover flange, and control the height of the bottom cover flange within 6 - 10 mm; Step 3. Forming of the top cover: Punch out a bile opening with a preset size on the top cover blank, turn over the edge at the bile opening to form a bile opening flange, and turn over the periphery of the top cover blank to form a top cover flange. The heights of both the bile opening flange and the top cover flange are controlled within the range of 3 - 8 mm; Step 4. Processing of the top cover: Press out a top cover concave platform and a plurality of top cover counterbores on the edge of the bile opening of the formed top cover blank above. Control the height of the top cover concave platform within 3 - 5 mm; Step 5. Welding screws to the bile opening of the top cover: Weld top cover screws to a plurality of top cover counterbores on the formed top cover blank; Step 6. Pressing the flange opening of the barrel body: Press the barrel body blank with a punching machine to form a heating flange opening, and punch out a barrel body concave platform and a barrel body convex platform on the edge of the heating flange opening. The heights of both the barrel body concave platform and the barrel body convex platform are controlled within 3 - 5 mm; Step 7. Flanging the flange opening of the barrel body: Turn over the heating flange opening of the barrel body blank with a punching machine, and control the height of the flange opening flange within 3 - 8 mm; Step 8. Bending the barrel body: Use a bending machine or die to punch the flanged barrel body blank to fold out the preset angle and arc of the barrel body, so that the barrel body forms a circle; Step 9. Butt welding of the barrel body: Weld one point at the upper and lower positions of the connection of the bent circular barrel body blank. Depending on the length dimension of the inner liner, positioning welding points can be added in the middle to fix the overlap; Step 10. Seam welding of the barrel body: Place the sheet material of the barrel body blank that has been butt welded and bent into shape on a seam welding machine, adjust the welding parameters, and perform seam welding operations to weld the entire length of the overlap; Step 11. Welding the nozzle: Weld the nozzle at the hole on the barrel body blank after seam welding; Step 12. Welding the flange screw: Weld the flange screw on the barrel body blank with the nozzle welded; Step 13. Seam welding of the bottom cover and the top cover with the top cover blank: Align the processed and formed bottom cover blank and top cover blank flush with the above barrel body blank, fix them with spot welding, and then perform seam welding for one week on a seam welding machine to complete the manufacturing of the inner liner.

2. The manufacturing method of an inner container of an electric water heater according to claim 1, characterized in that Install a sealing ring in the top cover concave platform, and a sealing cover is provided above the sealing ring.

3. The manufacturing method of an electric water heater inner container according to claim 1, characterized in that In step 5, the welding of the top cover blank and the top cover screw uses capacitive energy storage welding. Align the tip of the electrode vertically with the center of the head of the top cover screw to avoid offset resulting in poor welding. After pressing the welding machine, quickly release it to avoid continuous discharge burning through the plate. Check whether the top cover screw is stable after welding.

4. The manufacturing method of an inner container of an electric water heater according to claim 1, characterized in that In step 11, the welding of the barrel body blank and the nozzle uses a tungsten inert gas welding machine. Place the nozzle correctly at the hole of the barrel body blank and perform tungsten inert gas welding from the inside of the barrel body blank.

5. The manufacturing method of an inner container of an electric water heater according to claim 1, characterized in that In step 12, the welding of the barrel body blank and the flange screw uses capacitive energy storage welding. Align the tip of the electrode vertically with the center of the head of the flange screw to avoid offset resulting in poor welding. After pressing the welding machine, quickly release it to avoid continuous discharge burning through the plate. Check whether the flange screw is stable after welding.

6. The manufacturing method of an inner container of an electric water heater according to claim 1, characterized in that In step five, the capacitance of the capacitor for capacitor energy storage welding is: 500 - 1000 μF; the charging voltage is: 100 - 200 V; the discharge time is: 0.2 - 0.5 ms; the electrode pressure is: 2 - 4 MPa.

7. The manufacturing method of an electric water heater inner container according to claim 1, characterized in that In step ten, the welding alternating current of the seam welder is: 10 - 20 kA; the welding voltage is 1.8 - 2.8 V; the welding speed is: 3 - 5 m / min; the electrode pressure is: 15 - 22 MPa; the pulse frequency is: 0 - 200 Hz.

8. A manufacturing method of an inner tank of an electric water heater according to claim 1, characterized in that In step eleven, the welding current for seam welding is: 25 - 35 A; the weld width is: 3 - 4 mm; the argon flow rate is 8 - 10 L / min; arc extinguishing treatment: fill the crater to prevent cracks.

9. The manufacturing method of an inner container of an electric water heater according to claim 1, characterized in that In step twelve, capacitor energy storage welding is adopted, and its capacitance is: 500 - 1000 μF; the charging voltage is: 100 - 200 V; the discharge time is: 0.2 - 0.5 ms; the electrode pressure is: 2 - 4 MPa.

10. The manufacturing method of an inner container of an electric water heater according to claim 1, characterized in that In step twelve, the welding alternating current of the seam welder is: 10 - 20 kA; the welding voltage is 1.8 - 2.8 V; the welding speed is 3 - 5 m / min; the electrode pressure is 15 - 22 MPa; the pulse frequency is 50 - 200 Hz.

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