Machining method of special-shaped end cover of motor for continuous mining machine

Abstract

A machining method of a special-shaped end cover of a motor for a continuous mining machine relates to the technical field of production of motors for continuous mining machines, and comprises the following four procedures: designing the special-shaped end cover and carrying out rivet welding, annealing, turning and drilling on the special-shaped end cover, designing a first flange, a second flange, a cylinder and a hanging ring on the special-shaped end cover, and positioning by using a welding tire during rivet welding of the special-shaped end cover, the relative positions of the first flange and the second flange and the reinforcing ribs meet the design requirement, deformation is reduced through annealing procedure treatment, a datum plane is turned through a turning procedure, and then the locating circle datum, seam allowances at the front flange and the rear flange and an inner hole of the special-shaped end cover are turned to ensure that the concentricity meets the design requirement. When the special-shaped end cover of the continuous mining machine is machined through the special-shaped end cover machining method, use of castings is avoided, the machined special-shaped end cover well reserves a space for fastening bolts, the difference between the diameter of the special-shaped end cover and the diameter of the two flanges is small, and the machining cost of the special-shaped end cover is saved.

Description

Technical Field

[0001] The present invention relates to the technical field of production of motors for continuous miners, and in particular to a method for processing a special-shaped end cover of a motor for a continuous miner. The special-shaped end cover of the motor serves to fasten the motor and the continuous miner. The special-shaped end cover has a complex structure and is difficult to manufacture and process. Background Art

[0002] The motor end cover of the continuous mining machine is special-shaped. The flanges on both sides are of the same height and their respective thicknesses need to be guaranteed. In order to leave space for the fastening bolts between the two flanges, the diameter difference between the two flanges is relatively large. This component has a complex structure. If castings are used, the development of casting molds is difficult and expensive. Therefore, it is necessary to invent a new manufacturing and processing method for this special-shaped end cover. Summary of the Invention

[0003] In view of this, it is necessary to provide a method for processing a special-shaped end cover of a motor for a continuous mining machine.

[0004] A processing method for a special-shaped end cover of a motor for a continuous mining machine includes four processes: designing the special-shaped end cover, riveting and welding the special-shaped end cover, annealing, turning and drilling. The special-shaped end cover is designed with a first flange, a second flange, a cylinder and a lifting ring. Based on the cylinder, the first flange is loosely matched and installed on the outer circle positioning part of the cylinder so as to prevent axial movement. The second flange is loosely matched with the cylinder and installed on the plane of the cylinder. The first flange is welded to the cylinder and the second flange, the welded parts are annealed, the first flange and the second flange are inspected at the places where the lifting rings are to be welded, the lifting rings are aligned by using a welding jig, the lifting rings are welded, the whole is welded and annealed, and finally the whole is processed. When riveting and welding the special-shaped end cover, the welding jig is used for positioning. The relative positions of the first flange, the second flange and the reinforcement rib meet the design requirements. The annealing process is used to reduce deformation. The turning process is used to first turn out a reference surface, then turn the positioning circle reference and the stoppers at the front and rear flanges, and the concentricity of the inner hole of the special-shaped end cover meets the design requirements.

[0005] Preferably, the riveting and annealing process steps of the special-shaped end cover are: processing a U-shaped weld bead on the first flange, processing a U-shaped weld bead on the second flange, then processing a screw countersink, and processing a U-shaped weld bead on the cylinder; using a cylindrical positioning circle to install the first flange and the second flange, close to both sides, and weld the weld bead.

[0006] Preferably, since the welds of the first flange and the second flange are large and the deformation after welding is large, the welded parts are annealed. After heat treatment, in order to ensure the inner dimensions of the special-shaped end cover, the inner dimensions of the first flange and the second flange are knife-checked.

[0007] Preferably, the lifting ring is welded by controlling the relative position of the lifting ring and the second flange countersunk hole using a welding tool.

[0008] Preferably, the specific process steps of turning are: the four jaws of the turning machine clamp the outer circle of the second flange, align the end cover, and turn the first flange into a positioning stop for the tire; put on the high-leg tire, install the first flange on the tire, and process the plane of the second flange separately, remove it, and when processing the diameter size of the second flange, the tolerance needs to comply with the design drawing; turn over the workpiece, use the diameter size of the second flange for alignment, and then process the diameter size of the first flange.

[0009] Preferably, the workpiece is turned over, the diameter of the second flange is used for alignment, and 5 mm is removed from the plane of the first flange during machining.

[0010] Preferably, the specific process steps of drilling are: using the first diameter size of the first flange to install the drilling jig, drill the first hole required by the process, and detect the size of each hole; using the second diameter size of the second flange to install the drilling jig, drill the second hole required by the process, and detect the size of each hole; using the third diameter size of the inner hole of the end cover to install the drilling jig, drill the screw holes before and after the second flange, and detect the size of each hole; measurement: stand the special-shaped end cover on the workbench, and measure each size with the center line of the end cover as the reference; after the measurement is completed, the manufacturing and processing of the special-shaped end cover of the motor for the continuous miner is completed.

[0011] The present invention avoids the use of castings in processing the special-shaped end caps of continuous miners. The processed special-shaped end caps leave ample space for fastening bolts, and the diameter difference between the two flanges is relatively small, thus saving the processing cost of the special-shaped end caps. The present invention has the following beneficial effects:

[0012] Cost Advantages: Cast iron is relatively expensive, while steel and other materials used in welded parts can be relatively inexpensive, reducing raw material procurement costs. Cast iron parts typically require molds, which are expensive and time-consuming. Welded parts can be cut and welded according to actual needs, eliminating the need for molds. This reduces initial investment, processing time, and costs.

[0013] Advantages in performance: Strength and toughness. The selection of suitable steel materials and the adoption of reasonable welding processes for welded parts can achieve higher strength and good toughness, which can meet or even exceed the mechanical performance requirements of some cast iron parts and adapt to a variety of engineering application scenarios; Fatigue resistance. The integrity of the welded structure is good. When subjected to dynamic loads, the fatigue resistance is often better than that of cast iron parts, reducing the possibility of failure forms such as cracks due to fatigue.

[0014] Advantages in production flexibility: Design changes. If there are changes during the product design process, welded parts are easier to modify and adjust the structure. Only some welding parts need to be changed, while cast iron parts may need to be re-molded, which is costly and has a long cycle; customization. For small-batch, customized products, welded parts can respond quickly to production needs and can be flexibly assembled and welded according to specific size and shape requirements. However, due to mold limitations, small-batch production of cast iron parts is not economical.

[0015] Advantages in quality control: Defect detection: Weld defects such as porosity and slag inclusions are relatively easy to detect and locate through nondestructive testing methods, allowing for timely identification and repair, ensuring product quality. Quality stability: Modern welding equipment and processes can effectively control welding quality, resulting in a high degree of quality stability in welded parts.

[0016] In summary, the production process of cast iron parts is influenced by many factors, and quality fluctuations can be significant. Regarding environmental protection, the production process of cast iron parts produces a lot of pollutants such as dust and waste residue, while the production process of welded parts is relatively clean and produces fewer pollutants, meeting environmental protection requirements. Material recycling: Welded parts have a high material recycling rate, and scrapped materials such as steel can be easily recycled and reprocessed, while the recycling and processing of cast iron parts is relatively complex. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Schematic diagram of the special-shaped end cover structure;

[0018] Figure 2 for Figure 1 Schematic diagram of the medium AA perspective structure;

[0019] In the figure: first flange 1, second flange 2, cylinder 3, and lifting ring 4. DETAILED DESCRIPTION

[0020] In order to make the technical solution of the present invention easier to understand, the technical solution of the present invention is now clearly and completely described in the form of specific embodiments in conjunction with the accompanying drawings.

[0021] See also Figure 1 and Figure 2The processing method of the special-shaped end cover of the electric motor for a continuous mining machine includes four working steps: designing the special-shaped end cover and riveting, annealing, turning and drilling the special-shaped end cover. The special-shaped end cover is designed with a first flange 1, a second flange 2, a cylinder 3 and a lifting ring 4; based on the cylinder 3, the first flange 1 is loosely fitted and installed to the outer circle positioning tire of the cylinder 3 so that it cannot move axially. The second flange 2 is loosely fitted with the cylinder 3 and the second flange 2 is installed to the plane of the cylinder 3; the first flange 1 is welded to the cylinder 3 and the second flange 2, the welded parts are annealed, the first flange 1 and the second flange 2 where the lifting ring 4 needs to be welded are inspected by a tool, the lifting ring 4 is positioned using a welding jig, the lifting ring 4 is welded, the overall welding is annealed after completion, and the overall processing is finally performed. When riveting the special-shaped end cover, the welding fixture is used for positioning, and the relative positions of the first flange 1 and the second flange 2 and the reinforcement meet the design requirements: Since the countersunk hole of the special-shaped end cover has been processed, it is necessary to ensure the relative position and angle between the lifting ring and the countersunk hole and the subsequent hole to be processed in the first flange 1. It is necessary to use a welding table to ensure the relative position of the lifting ring 4 to the outer circle of the special-shaped end cover. The annealing process is used to reduce deformation. The turning process is used to first turn out the reference surface, and then turn the positioning circle reference and the stop at the front and rear flanges. The concentricity of the inner hole of the special-shaped end cover is guaranteed to meet the design requirements.

[0022] The process steps of riveting, welding and annealing of the special-shaped end cover are as follows: processing a U-shaped weld bead on the first flange 1, processing a U-shaped weld bead on the second flange 2, then processing a screw countersink Φ28mm deep 25mm, and processing a U-shaped weld bead on the cylinder 3; using the cylinder 3Φ392mm positioning circle to install the first flange 1 and the second flange 2, close to both sides, and weld the welds.

[0023] Since the welds of the first flange 1 and the second flange 2 are large and the deformation after welding is large, the welded parts are annealed. After heat treatment, in order to ensure the 90mm size of the inner side of the special-shaped end cover, the inner side dimensions of the first flange 1 and the second flange 2 are knife-checked.

[0024] The relative position of the lifting ring and the countersunk hole of the second flange 2 is controlled by welding the lifting ring 4.

[0025] The specific process steps of turning are: the four-jaw turning machine clamps the outer circle of the second flange 2, aligns the end cover, and turns the first flange 1 into the positioning stop of the tire; installs the high-foot tire, installs the first flange 1 on the tire, and processes the plane of the second flange 2 respectively, removing 5mm, and then processing the Φ500mm, Φ430mm, and Φ215mm sizes of the second flange 2. The tolerances need to comply with the design drawings; flip the live part, use the Φ430mm and Φ215mm sizes of the second flange 2 for alignment, process the plane of the first flange 1 to remove 5mm, and then process the Φ500mm, Φ392mmh8, and Φ312mm sizes of the first flange 1. The tolerances need to comply with the design drawings.

[0026] The specific process steps for drilling are: use the first diameter size Φ392h8mm of the first flange 1 to install the drilling jig, drill a 10xΦ22mm first hole, and check the size of each hole; use the second diameter size Φ430mm of the second flange 2 to install the drilling jig, drill a 16xΦ17.5mm second hole, and check the size of each hole; use the third diameter size Φ215mm of the inner hole of the end cover to install the drilling jig, drill the M12 screw holes before and after the second flange 2, and check the size of each hole; measurement: place the special-shaped end cover on the workbench, and measure each size based on the center line of the end cover; after the measurement is completed, the manufacturing and processing of the special-shaped end cover of the continuous miner motor is completed.

[0027] The present invention is used to process the special-shaped end cover of the continuous miner, thereby avoiding the use of castings. The processed special-shaped end cover leaves a good space for fastening bolts, and the diameter difference between the two flanges is small, which saves the processing cost of the special-shaped end cover, improves product quality and performance, and meets the needs of energy saving and environmental protection.

[0028] It should be noted that the embodiments described herein are only some embodiments of the present invention, not all implementations of the present invention. The embodiments are merely illustrative and serve only to provide a more intuitive and clear way to understand the content of the present invention, rather than to limit the technical solutions described in the present invention. Without departing from the concept of the present invention, all other implementations that can be thought of by ordinary technicians in this field without making creative efforts, as well as other simple replacements and various variations of the technical solutions of the present invention, are within the scope of protection of the present invention.

Claims

1. A method for processing a special-shaped end cover of a motor for a continuous miner, characterized by: The processing method of the special-shaped end cover of the electric motor for the continuous mining machine includes four processes: design of the special-shaped end cover and riveting, annealing, turning and drilling of the special-shaped end cover. The special-shaped end cover is designed with a first flange, a second flange, a cylinder and a lifting ring. The cylinder is used as the basis, the first flange is clearance-matched and installed on the outer circle positioning tire of the cylinder so that it cannot move axially. The second flange is clearance-matched with the cylinder and the second flange is installed on the cylinder plane; the first flange is welded to the cylinder and the second flange, the welded parts are annealed, the first flange and the second flange are inspected for the places where the lifting rings need to be welded, the lifting rings are aligned using a welding jig, the lifting rings are welded, the overall welding is completed, annealing is performed, and finally the overall processing is performed; when the special-shaped end cover is riveted, the welding jig is used for positioning, the relative positions of the first flange and the second flange and the reinforcement ribs meet the design requirements, the annealing process is used to reduce deformation, the turning process is used to first turn out the reference surface, and then the positioning circle reference and the stop at the front and rear flanges are turned, and the concentricity of the inner hole of the special-shaped end cover meets the design requirements.

2. The method for processing a special-shaped end cover of a continuous miner motor according to claim 1, wherein: The process steps for riveting, welding and annealing of the special-shaped end cover are as follows: process a U-shaped weld bead on the first flange, process a U-shaped weld bead on the second flange, then process the screw countersunk holes, and process a U-shaped weld bead on the cylinder; use the cylindrical positioning circle to install the first flange and the second flange, close them to both sides, and weld the weld bead.

3. The method for processing the special-shaped end cover of the motor for the continuous miner according to claim 1, characterized in that: Since the welds of the first flange and the second flange are large and the deformation after welding is large, the welded parts are annealed. After heat treatment, in order to ensure the inner dimensions of the special-shaped end cover, the inner dimensions of the first flange and the second flange are knife-checked.

4. The method for processing a special-shaped end cover of a continuous miner motor according to claim 1, wherein: The welding ring is welded by controlling the relative position of the lifting ring and the second flange countersunk hole using a welding fixture.

5. The method for processing the special-shaped end cover of the motor for the continuous miner according to claim 1, characterized in that: The specific process steps of turning are: the four jaws of the turning machine clamp the outer circle of the second flange, align the end cover, and turn the first flange into the positioning stop of the tire; install the high-foot tire, install the first flange on the tire, and process the plane of the second flange separately, remove it, and when processing the diameter size of the second flange, the tolerance needs to comply with the design drawing; turn the workpiece over, use the diameter size of the second flange for alignment, and then process the diameter size of the first flange.

6. The method for processing a special-shaped end cover of a motor for a continuous miner according to claim 5, characterized in that: Turn the workpiece over, use the diameter of the second flange for alignment, and remove 5mm from the first flange surface.

7. The method for processing a special-shaped end cover of a continuous miner motor according to claim 1, wherein: The specific process steps of drilling are: use the first diameter size of the first flange to install the drilling jig, drill the first hole required by the process, and detect the size of each hole; use the second diameter size of the second flange to install the drilling jig, drill the second hole required by the process, and detect the size of each hole; use the third diameter size of the inner hole of the end cover to install the drilling jig, drill the screw holes before and after the second flange, and detect the size of each hole; measurement: stand the special-shaped end cover on the workbench, and measure each size with the center line of the end cover as the reference; after the measurement is completed, the manufacturing and processing of the special-shaped end cover of the continuous mining machine motor is completed.

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