Large storage tank cylinder section vertical hobbing and welding integrated manufacturing device and manufacturing method

Abstract

The invention provides a vertical hobbing-milling-welding integrated manufacturing device and method for a large storage tank cylinder section. The vertical hobbing-milling-welding integrated manufacturing device comprises a driving roller, a first supporting roller, a second supporting roller, a main shaft, a rotary driving assembly, a first moving assembly, a second moving assembly and a third moving assembly. The first moving assembly drives the first supporting roller and the second supporting roller to do reciprocating rectilinear motion in the first direction, the second moving assembly drives the driving roller and the third moving assembly to do reciprocating rectilinear motion in the second direction, and the third moving assembly drives the main shaft to do reciprocating rectilinear motion in the third direction. The first direction, the second direction and the third direction are perpendicular to one another; the first supporting roller and the second supporting roller are arranged between the driving roller and the main shaft; the rotary driving assembly drives the driving roller, the first supporting roller and the second supporting roller to rotate, and a milling cutter or a stirring head is arranged on the main shaft.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metal plastic forming, in particular to a large tank cylinder segment vertical roll-milling welding integrated manufacturing device and method. BACKGROUND

[0002] In recent years, the world spaceflight has entered a new stage represented by large-scale constellation networking, space resource development and utilization, etc. High-density launch of carrier rockets has become the new normal. How to improve the efficiency of rocket manufacturing and reduce the manufacturing cost while ensuring the quality of rocket manufacturing has become the focus of attention of major space powers. Large tanks are important structural components and main load-bearing parts of carrier rockets, and they also store the fuel for the launch of rockets. The manufacturing quality of the tank is related to the reliability and safety of the flight of the carrier rocket, and the manufacturing efficiency and cost have a very important influence on the manufacturing cycle and cost control of the whole rocket.

[0003] The cylinder segment is one of the two main components of the tank, mainly used to form the outer shape of the tank cylinder, and to bear the axial compression load of the rocket body and the internal pressure of the tank during flight. Currently, the cylinder segment is mainly manufactured by welding 4-5 curved wall plates together in a circumferential direction, which involves welding 4-5 longitudinal seams. During the manufacturing of the curved wall plates, the roll-bending forming method is often used to bend the flat surface into a curved surface, and then milling is performed before it can be used for welding.

[0004] The existing Chinese patent application with publication number CN118635325A discloses a large thin-walled tank cylinder segment integral precise bending forming system and method, which relates to the technical field of metal plastic forming and solves the problem of integral precise bending forming of large thin-walled tank cylinder segments. Specifically, it first builds a roll-bending tooling mainly composed of an electric feeding platform, axial limiting devices, and radial auxiliary supports, etc. During the roll-bending process of the super-long wall plate, the guide rollers on the axial limiting devices on both sides clamp the two sides of the super-long wall plate, keeping it in a clamped state during the roll-bending process to prevent lateral slipping and eliminate the occurrence of edge misalignment after closure. This patent application uses a super-long wall plate to replace the traditional 4-5 small wall plates, and based on a horizontal roll-bending machine, the super-long wall plate is integrally roll-bent and formed into an open cylinder segment. Only one longitudinal seam welding is needed to obtain a closed cylinder segment product, which significantly reduces the number of cylinder segment welds, improves the structural reliability of the cylinder segment, and shortens the cylinder segment manufacturing process. The main problem is that the super-long wall plate is in a horizontal position during horizontal roll-bending, and due to the influence of gravity, the curvature of the outer shape formed by roll-bending cannot be accurately detected on the machine. It must be measured after the roll-bent cylinder segment is lifted off the machine and placed vertically. If the measured dimensions are out of tolerance, the roll-bending process must be repeated. This process is very time-consuming and requires the configuration of side and upper supporting devices to adjust the side and upper supporting forces to offset the changing gravitational moment during the forming process, which makes the operation process complex.

[0005] The existing Chinese patent application with publication number CN114798842A discloses a CNC four-axis vertical roll bending forming equipment, which relates to the field of sheet metal rolling equipment. It includes an upper frame connected to left and right connecting beams and fixedly mounted on the chassis. The front axle, rear axle, left axle, and right axle are parallel to each other and perpendicular to the chassis and are respectively mounted on the upper frame and the lower frame. Bearings are respectively installed at both ends of the front axle and are fixedly mounted on the upper frame and the lower frame through the bearings. This patent application adopts a vertical feeding method. The forming process is basically not affected by the deadweight of the sheet metal and does not require additional material support. It can achieve accurate measurement of the rolling curvature on the machine and is very convenient to operate. However, when used for forming tank barrel sections, after completing the vertical roll bending of the barrel section, the obtained open barrel section still needs to be transferred to the milling machine for milling and then transported to the welding equipment for joint welding. The entire process is still very cumbersome.

[0006] The existing technology for manufacturing barrel segments requires three completely different specialized processing units for rolling, milling, and welding. This involves transferring and loading four to five panels between these units, which is time-consuming. Furthermore, barrel segments manufactured using this method often have weak welds, resulting in low manufacturing efficiency and difficulty meeting the high-quality and efficient production requirements for subsequent barrel segments. Summary of the Invention

[0007] In view of the defects in the prior art, the purpose of the present invention is to provide a large tank barrel segment vertical rolling milling and welding integrated manufacturing device and manufacturing method.

[0008] According to the present invention, a large tank barrel segment vertical rolling milling and welding integrated manufacturing device includes a driving roller, a first support roller, a second support roller, a main shaft, a rotary drive assembly, a first moving assembly, a second moving assembly, and a third moving assembly; The first moving assembly drives the first support roller and the second support roller to perform linear reciprocating motion in the first direction, the second moving assembly drives the active roller and the third moving assembly to perform linear reciprocating motion in the second direction, and the third moving assembly drives the main shaft to perform linear reciprocating motion in the third direction; The first direction, the second direction and the third direction are perpendicular to each other; The first support roller and the second support roller are both arranged between the driving roller and the main shaft; The rotary drive assembly drives the active roller, the first support roller and the second support roller to rotate respectively.

[0009] Preferably, the active roller comprises a main section roller and a main movable side plate, the main section roller comprises a main section, and the main section roller is matched with the main movable side plate to form a round roller state; The first supporting roller includes a first section roller and a first movable side plate, the first section roller includes a first section, and the first section roller is matched with the first movable side plate to form a round roller state through the first section; The first sections include two sections, which are perpendicular to each other and arranged on the same line; The second supporting roller includes a second section roller and a second movable side plate, the second section roller includes a second section, and the second section roller is matched with the second movable side plate through the second section to form a round roller state; The second sections include two sections, which are perpendicular to each other and arranged on the same line.

[0010] Preferably, a square groove is opened in the middle of the main section, and the length of the square groove is the same as the length of the main section.

[0011] Preferably, a milling cutter or a stirring head is provided on the main shaft, and the rotation of the main shaft drives the milling cutter or the stirring head to work; When a milling cutter is provided on the spindle, the device includes a milling processing module; When a stirring head is provided on the main shaft, the device comprises a friction stir welding module.

[0012] Preferably, the machine further comprises a frame, wherein the frame comprises an upper base plate and a lower base plate, and at least one set of a first moving assembly, a second moving assembly and a third moving assembly is respectively arranged on the upper base plate and / or the lower base plate; The upper end and / or lower end of the first supporting roller is connected to the first moving assembly; The upper end and / or lower end of the second supporting roller is connected to the first moving assembly; The upper end and / or lower end of the active roller is connected to the second moving assembly; The upper end and / or the lower end of the third moving component is connected to the second moving component.

[0013] Preferably, the upper base plate includes a first upper base plate and a second upper base plate, the distance between the first upper base plate and the lower base plate is equal to the distance between the second upper base plate and the lower base plate, the first upper base plate and the second upper base plate are connected with a gap, and the gap allows the barrel section to pass through.

[0014] Preferably, the first moving assembly includes a first lead screw, a first slider and a first moving drive servo motor, the first slider is connected to the first lead screw, and the first moving drive servo motor drives the first lead screw to rotate, thereby driving the first slider to perform linear motion; The second moving assembly includes a second lead screw, a second slider, and a second moving drive servo motor. The second slider is connected to the second lead screw. The second moving drive servo motor drives the second lead screw to rotate, thereby driving the second slider to perform linear motion. The third moving assembly includes a third lead screw, a third slider, and a third moving drive servo motor. The third slider is connected to the third lead screw. The third moving drive servo motor drives the third lead screw to rotate, thereby driving the third slider to perform linear motion. The first lead screw is arranged to intersect the second lead screw at right angles, and the third lead screw is arranged to intersect the second lead screw at right angles.

[0015] Preferably, the rotation drive assembly includes a rotation drive servo motor, and the rotation drive servo motor includes three groups, and the three groups of rotation drive servo motors respectively drive the active roller, the first support roller and the second support roller to perform rotational motion.

[0016] Preferably, it further comprises a feed wheel group and a discharge wheel group, wherein the feed wheel group comprises a plurality of feed rollers arranged parallel to each other, and the discharge wheel group comprises a plurality of discharge rollers arranged in an arc shape.

[0017] The present invention also provides a method for vertical rolling milling and welding integrated manufacturing of large tank barrel segments, comprising the following steps: Step S1: Preset stage: according to the preset diameter of the barrel section after rolling, the distance between the first support roller and the second support roller is set and the first support roller and the second support roller are driven to the set position; Step S2: Roll forming stage: Step S2.1: Push one end of the upright flat sheet between the driving roller and the first and second support rollers, so that the processed surface of the flat sheet contacts the surfaces of the first and second support rollers; Step S2.2: Control the active roller to move toward the middle between the first support roller and the second support roller to bend the end of the flat sheet; Step S2.3: driving the first support roller and the second support roller to rotate, gradually rolling the flat sheet into a cylindrical section of a preset diameter; Step S3 transition phase: Step S3.1: Separate the driving roller from the first support roller and the second support roller, remove the main movable side plate, the first movable side plate, and the second movable side plate, leaving the main section roller, the first section roller, and the second section roller; Step S3.2: driving the main section roller to rotate until the center line of the main section in the longitudinal direction intersects the axis of the main shaft at right angles, and driving the first section roller and the second section roller to rotate until one of the first sections of the first section roller and one of the second sections of the second section roller are parallel to the main section, and the other first section of the first section roller and the other second section of the second section roller are parallel to and opposite to each other; Step S4: milling process: Step S4.1: driving the main section roller to move toward the first section roller and the second section roller to clamp the joint of the barrel section; Step S4.2: Install a milling cutter on the spindle, and drive the spindle to move close to the process margin of the joint of the barrel section; Step S4.3: driving the spindle to rotate and move the spindle up and down, so that the milling cutter performs milling processing on the process edge at a set cutting depth until the process edge is removed; Step S5: Friction stir welding stage: Step S5.1: Control the main section roller, the first section roller, and the second section roller to separate from the barrel section joint, manually close the barrel section joint, and control the main section roller, the first section roller, and the second section roller to feed toward the barrel section joint again to re-clamp the barrel section joint; Step S5.2: Install a stirring head on the main shaft, and drive the main shaft until the stirring head is close to the upper part of the joint of the barrel section and close to the outer surface of the barrel section; Step S5.3: Control the main shaft to rotate and drive the main shaft to move forward a set distance, and drive the main shaft to move downward to enable the stirring head to perform longitudinal friction stir welding on the joint of the barrel section.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. The manufacturing device of the present invention integrates the three functions of barrel segment rolling, edge milling, and welding into one, allowing the processes that originally required three different dedicated processing devices to be completed on one device. This greatly reduces the workload of material transportation and loading between different devices, significantly improves manufacturing efficiency, and reduces manufacturing costs. 2. The manufacturing device of the present invention improves manufacturing efficiency by setting the active roller, the first support roller and the second support roller to two states: one is a round roller state, in which the barrel section is rolled and bent; the other is a cross-section roller state, in which the barrel section is milled and welded; 3. The manufacturing device of the present invention provides a square groove on the main section, which can avoid the milling cutter or stirring head on the one hand, and on the other hand, uses the square groove to position the main section roller, so that the position of the main section roller and the main shaft are matched, which is conducive to accurate milling and welding of barrel sections. 4. The manufacturing method of the present invention uses a single piece of extra-long sheet metal as a blank to manufacture the barrel section, enabling the integral formation of large tank barrel sections. The manufactured barrel section has only one weld seam, significantly reducing the number of weld seams compared to conventional barrel sections welded from four to five small blanks. This significantly improves structural reliability and greatly shortens the assembly and welding process. 5. The manufacturing method of the present invention adopts a vertical rolling bending process instead of the traditional horizontal rolling bending process, which can solve the influence of the changing gravity moment caused by the movement of the center of gravity of the sheet metal during the rolling bending process on the rolling deformation, improve the manufacturing accuracy of the cylinder section, and the curvature of the outer surface of the rolled cylinder section can be accurately measured on the machine without having to be taken off the machine and placed upright for measurement. Therefore, in-situ detection of rolling deformation and in-situ adjustment of rolling process parameters can be achieved, which solves the problem that the horizontal rolling machine needs to be repeatedly put on the machine for rolling and then taken off the machine for inspection, which is cumbersome and time-consuming. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other features, objects and advantages of the present invention will become more apparent upon reading the detailed description of non-limiting embodiments with reference to the following drawings: Figure 1 A schematic diagram mainly showing the structure of the manufacturing device of the present invention; Figure 2 A schematic diagram mainly showing the structure of the manufacturing device of the present invention; Figure 3 An exploded view mainly showing the active roller, the first support roller and the second support roller of the present invention; Figure 4 A schematic diagram mainly embodies the clamping of the active roller and the support roller on the joint of the roll-bent forming cylinder section of the present invention; Figure 5 A schematic diagram showing the roll-bending process of a tank barrel section according to the present invention; Figure 6 A schematic diagram mainly embodies the process of milling the residual edge of the tank barrel section and welding the joint portion of the tank barrel section according to the present invention; Figure 7 The main principle diagram of the present invention is to perform milling of the residual edge of the tank barrel section; Figure 8 The diagram mainly embodies the principle of friction stir welding of the joint of the tank barrel section according to the present invention.

[0020] As shown in the figure: DETAILED DESCRIPTION

[0021] The present invention will be described in detail below with reference to specific embodiments. The following examples will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those skilled in the art, several changes and improvements can be made without departing from the scope of the present invention. These all fall within the scope of protection of the present invention.

[0022] The present invention provides a vertical, integrated rolling, milling, and welding manufacturing device for large tank barrel segments. The device comprises a frame 1, a feed roller assembly 2, a discharge roller assembly 3, a driving roller 4, a first support roller 5, a second support roller 6, multiple rotational drive servo motors 7, multiple rotational drive reducers 8, multiple movement drive servo motors, multiple movement drive reducers, multiple lead screws, multiple sliders, a spindle 14, and a control cabinet 13. The control cabinet 13 houses a numerical control system that controls the operation of the driving roller 4, the first support roller 5, the second support roller 6, and the spindle 14 in different states. The manufacturing device comprises three processing modules: a vertical, numerically controlled three-axis rolling module, a milling module, and a friction stir welding module.

[0023] Specifically, if Figure 1 and Figure 2 As shown, the manufacturing device of the present invention includes a driving roller 4, a first support roller 5, a second support roller 6, a main shaft 14, a rotary drive assembly, a first movable assembly, a second movable assembly, and a third movable assembly. The first movable assembly drives the first support roller 5 and the second support roller 6 to perform linear reciprocating motion in a first direction, respectively. The second movable assembly drives the driving roller 4 and the third movable assembly to perform linear reciprocating motion in a second direction, respectively. The third movable assembly drives the main shaft 14 to perform linear reciprocating motion in a third direction. The first, second, and third directions are perpendicular to each other. The first support roller 5 and the second support roller 6 are both disposed between the driving roller 4 and the main shaft 14. The rotary drive assembly drives the driving roller 4, the first support roller 5, and the second support roller 6 to perform rotational motion, respectively.

[0024] The first direction, the second direction and the third direction can form a three-dimensional coordinate system, and the first direction is set as the direction of the X-axis, the second direction is set as the direction of the Y-axis, and the third direction is set as the direction of the Z-axis. The intersection point of the first movable component in the first direction and the second movable component in the second direction is the origin of the three-dimensional coordinate system. The first support roller 5 and the second support roller 6 can be symmetrically arranged or moved relative to the origin, and the active roller 4 and the third movable component can be symmetrically arranged or moved relative to the origin. The barrel section also passes through this origin after entering the device.

[0025] Specifically, if Figure 3 and Figure 4As shown, the main roller 4 includes a main cross-section roller 4a and a main movable side plate 4b, the main cross-section roller 4a includes a main cross-section, and the main cross-section roller 4a matches with the main movable side plate 4b through the main cross-section to form a round roller state. The first support roller 5 includes a first cross-section roller 5a and a first movable side plate 5b, the first cross-section roller 5a includes a first cross-section, and the first cross-section roller 5a matches with the first movable side plate 5b through the first cross-section to form a round roller state, and the first cross-section includes two, and the two first cross-sections are perpendicular to each other and arranged in line. The second support roller 6 includes a second cross-section roller 6a and a second movable side plate 6b, the second cross-section roller 6a includes a second cross-section, and the second cross-section roller 6a matches with the second movable side plate 6b through the second cross-section to form a round roller state, and the second cross-section includes two, and the two second cross-sections are perpendicular to each other and arranged in line.

[0026] Specifically, the first moving assembly includes a first lead screw 11, a first sliding block 12, a first moving drive servo motor 9 and a first moving drive speed reducer 10, the first sliding block 12 is centrally provided with a threaded hole and is connected with the first lead screw 11 through threads, the first moving drive servo motor 9 drives the first lead screw 11 to rotate through the first moving drive speed reducer 10, and in turn drives the first sliding block 12 to move linearly. The second moving assembly includes a second lead screw 16, a second sliding block 22, a second moving drive servo motor 17 and a second moving drive speed reducer 18, the second sliding block 22 is centrally provided with a threaded hole and is connected with the second lead screw 16 through threads, the second moving drive servo motor 17 drives the second lead screw 16 to rotate through the second moving drive speed reducer 18, and in turn drives the second sliding block 22 to move linearly. The third moving assembly includes a third lead screw 15, a third sliding block 21, a third moving drive servo motor 19 and a third moving drive speed reducer 20, the third sliding block 21 is centrally provided with a threaded hole and is connected with the third lead screw 15 through threads, the third moving drive servo motor 19 drives the third lead screw 15 to rotate through the third moving drive speed reducer 20, and in turn drives the third sliding block 21 to move linearly. The first lead screw 11 and the second lead screw 16 are arranged perpendicularly, and the third lead screw 15 and the second lead screw 16 are arranged perpendicularly.

[0027] The moving drive servo motor and the moving drive speed reducer are used in cooperation, the rotating speed of the servo motor is generally fast, the torque of the servo motor can be enlarged after being reduced by the speed reducer, and the speed is not too fast, so that the lead screw can be driven to rotate at a relatively low rotating speed, and the sliding block connected with the lead screw through threads can move linearly after the lead screw rotates.

[0028] A feasible implementation is as follows: the frame 1 includes an upper base plate and a lower base plate, and at least one group of first movable components, a second movable component and a third movable component are respectively arranged on the upper base plate and / or the lower base plate, the upper end and / or the lower end of the first support roller 5 is connected to the first movable component, the upper end and / or the lower end of the second support roller 6 is connected to the first movable component, the upper end and / or the lower end of the active roller 4 is connected to the second movable component, and the upper end and / or the lower end of the third movable component is connected to the second movable component. A group of first movable components, a group of second movable components and a group of third movable components can be uniformly arranged on the upper base plate, the upper ends of the first support roller 5 and the second support roller 6 are respectively connected to the first movable component, and the upper ends of the active roller 4 and the third lead screw 15 are respectively connected to a group of second movable components. A group of first movable components, a group of second movable components and a group of third movable components can also be uniformly arranged on the lower base plate, and the arrangement method is similar. It is preferred that one group of first movable components, one group of second movable components and one group of third movable components are symmetrically arranged on the upper base plate and the lower base plate at the same time, the upper end and lower end of the first support roller 5 and the second support roller 6 are respectively connected to the first movable component, and the upper end and lower end of the active roller 4 and the third movable component are respectively connected to the second movable component.

[0029] More specifically, the upper base plate includes a first upper base plate and a second upper base plate. The distance between the first upper base plate and the lower base plate is equal, and the two upper base plates are located at the same height. The first upper base plate and the second upper base plate are connected to each other through a gap that allows the passage of the barrel section 25. The first upper base plate and the second upper base plate are connected to the lower base plate via a first bracket and a second bracket, respectively. The first bracket is connected to one end of the first upper base plate, and the second bracket is connected to one end of the second upper base plate. The other end of the first upper base plate is not connected to the other end of the second upper base plate, forming a certain gap between the two. This gap allows the barrel section 25 to be removed from between the upper and lower base plates.

[0030] The feed wheel group 2 of this manufacturing device includes a plurality of feed rollers arranged parallel to each other, and the plurality of feed rollers are installed in front of the frame. The discharge wheel group 3 includes a plurality of discharge rollers arranged in an arc shape, and the plurality of discharge rollers are arranged in an arc shape on the left side of the frame.

[0031] like Figure 5As shown, the CNC three-axis roll bending module includes a driving roller 4, a first support roller 5, and a second support roller 6. All three are driven to rotate by independent rotational drive servo motors 7 and rotational drive reducers 8. The driving roller 4, the first support roller 5, and the second support roller 6 are all driven to move linearly by independent movement drive servo motors and movement drive reducers. Through the linear movement and rotational movement of the three rollers, the flat blank can be rolled into a cylindrical segment. Specifically, the first support roller 5 and the second support roller 6 are each driven to move linearly by a corresponding first moving assembly. The first movement drive servo motor 9 drives the first slider 12 to move linearly. The first support roller 5 and the second support roller 6 are respectively mounted on the first slider 12. The movement of the first slider 12 drives the first support roller 5 and the second support roller 6 to move linearly. The driving roller 4 is driven to move linearly by the second moving assembly. The second movement drive servo motor 17 drives the second slider 22. The driving roller 4 and the third moving assembly are both mounted on the second slider 22. The movement of the second slider 22 drives the driving roller 4 and the third moving assembly to move linearly. The first moving drive servo motor 9 and the second moving drive servo motor 17 respectively drive the first slider 12 and the second slider 22 to move linearly, thereby controlling the first support roller 5, the second support roller 6 and the active roller 4 to move closer to or farther away from each other.

[0032] Preferably, the active roller 4 has a diameter of 400 mm and a length of 2000 mm, while the first and second support rollers 5 and 6 each have a diameter of 200 mm and a length of 2000 mm. The active roller 4 comprises a main-section roller 4a and a main movable side plate 4b with a width of 150 mm. The first support roller 5 comprises a first-section roller 5a and two first movable side plates 5b with a width of 150 mm. The second support roller 6 comprises a second-section roller 6a and two second movable side plates 6b. The main movable side plates 4b, the first movable side plates 5b, and the second movable side plates 6b all have countersunk holes and can be connected to the main-section roller 4a, the first-section roller 5a, and the second-section roller 6a, respectively, using three M10 screws to form a complete circular roller. The two first sections of the first-section roller 5a are perpendicular and collinear to each other, while the two second sections of the second-section roller 6a are perpendicular and collinear to each other.

[0033] like Figures 6 to 8 As shown, the milling processing module and the friction stir welding module share a set of core components such as a control cabinet 13, a spindle 14, a lead screw, a mobile drive servo motor, a mobile drive reducer, and a slider.

[0034] The spindle 14 rotates at a speed ranging from 1000 r / min to 3000 r / min. When the diamond milling cutter 23 is installed on the spindle 14, it forms a milling processing module together with the first moving assembly, the second moving assembly, the third moving assembly, the main section roller 4a, the first section roller 5a and the second section roller 6a. Figure 7As shown, the second moving component and the first moving component respectively drive the main section roller 4a, the first section roller 5a and the second section roller 6a to make linear motions and approach each other to achieve the clamping of the closing part of the rolled forming cylinder section 25, and then the second moving component drives the high-speed rotating diamond milling cutter 23 on the main shaft 14 to move to the top of the process margin of the closing part, and then the third moving component controls the main shaft 14 to move downward to achieve the milling removal of the process margin.

[0035] When the friction stir welding heat-resistant die steel stirring head 24 is installed on the main shaft 14, it forms a friction stir welding module together with the first moving assembly, the second moving assembly, the third moving assembly, the main section roller 4a, the first section roller 5a and the second section roller 6a. Figure 8 As shown, the second moving component and the first moving component respectively drive the main section roller 4a, the first section roller 5a and the second section roller 6a to make linear motions and approach each other to achieve the clamping of the closing part of the barrel section 25 after milling, and then the second moving component drives the rotating stirring head 24 on the main shaft 14 to move to the upper part of the closing part, and then the third moving component controls the main shaft 14 to move downward to achieve longitudinal welding of the closing part, and weld the open barrel section into a closed barrel section 25.

[0036] A rectangular groove of the same length as the main section of the main section roller 4a of the active roller 4 is opened in the middle of the main section. The position of the main section roller 4a is based on the perpendicular intersection of the center line of the rectangular groove in the longitudinal direction and the axis of the main shaft. The position of the main section roller 4a is matched with the main shaft 14, thereby more accurately milling and welding the barrel section 25. The rectangular groove is preferably 30mm wide, 30mm deep, and 2000mm long. The depth of the rectangular groove meets the requirement that the main section roller 4a avoids the milling cutter or mixing head.

[0037] The manufacturing device of the present invention integrates a CNC three-axis rolling forming module, a milling processing module, and a stir welding module, wherein the milling processing module and the stir friction welding module share a main shaft, which can be installed with both a milling cutter and a stirring head. When using the device to manufacture barrel sections, the flat blank containing process margins in an upright state is first three-axis rolled into a cylindrical shape, and then the milling processing module is used to mill and remove the process margins of the rolled joint. Finally, the stir friction welding module is used to longitudinally weld the joint to realize barrel section manufacturing. The present invention uses a single device to complete the barrel section manufacturing process that can only be completed by three conventional devices, which greatly reduces the workload of transporting materials between different devices. The use of a full-process vertical processing method can significantly improve the manufacturing efficiency and manufacturing accuracy of the barrel section.

[0038] The present invention also provides a high-efficiency manufacturing method for vertical roller milling and welding of large tank barrel segments, comprising the following steps: Step S1: Presetting stage: according to the preset diameter of the barrel section 25 after rolling, the distance between the first support roller 5 and the second support roller 6 is set and the first support roller 5 and the second support roller 6 are driven to the set position; Step S2: Roll forming stage: Step S2.1: Push one end of the upright flat sheet material between the driving roller 4 and the first and second support rollers 5, 6, so that the processed surface of the flat sheet material contacts the surfaces of the first and second support rollers 5, 6; Step S2.2: Control the active roller to move toward the middle between the first support roller 5 and the second support roller 6 to bend the end of the flat sheet; Step S2.3: driving the first support roller 5 and the second support roller 6 to rotate, gradually rolling the flat blank into a cylindrical section 25 of a preset diameter; Step S3 transition phase: Step S3.1: Separate the active roller 4 from the first support roller 5 and the second support roller 6, remove the main movable side plate 4b, the first movable side plate 5b, and the second movable side plate 6b, and leave the main section roller 4a, the first section roller 5a, and the second section roller 6a; Step S3.2: Drive the main section roller 4a to rotate until the centerline of the main section in the longitudinal direction intersects the axis of the main shaft 14 at right angles, and drive the first section roller 5a and the second section roller 6a to rotate until one of the first sections of the first section roller 5a and one of the second sections of the second section roller 6a are parallel to the main section, and the other first section of the first section roller 5a and the other second section of the second section roller 6a are parallel to and opposite to each other; Step S4: milling process: Step S4.1: driving the main section roller 4a to move toward the first section roller 5a and the second section roller 6a to clamp the closing section of the barrel section 25; Step S4.2: Install a milling cutter on the spindle 14, and drive the spindle 14 to move close to the process margin of the joint of the barrel section 25; Step S4.3: driving the spindle 14 to rotate and move the spindle 14 up and down, so that the milling cutter performs milling processing on the process edge at a set cutting depth until the process edge is removed; Step S5: Friction stir welding stage: Step S5.1: Control the main section roller 4a, the first section roller 5a, and the second section roller 6a to separate from the closing portion of the barrel section 25, manually close the closing portion of the barrel section 25, and control the main section roller 4a, the first section roller 5a, and the second section roller 6a to feed toward the closing portion of the barrel section 25 again to re-clamp the closing portion of the barrel section 25; Step S5.2: Install a stirring head on the main shaft 14, and drive the main shaft 14 until the stirring head is close to the upper part of the joint of the barrel section 25 and close to the outer surface of the barrel section; Step S5.3: Control the main shaft 14 to rotate and drive the main shaft 14 to move forward a set distance, and drive the main shaft 14 to move downward to enable the stirring head to perform longitudinal friction stir welding on the joint of the barrel section 25.

[0039] Taking the example of manufacturing a ribbed flat blank having a length of 11948 mm (with process margins of 8 mm width and 5 mm thickness at both ends in the longitudinal direction) into a cylinder section 25 having an outer surface diameter of 3800 mm, the specific steps of the manufacturing method are as follows: Step 1: Connect the active roller 4, the first support roller 5, and the second support roller 6 into a circular roller state through the cross-section roller and the movable side plate. According to the outer surface diameter of the cylinder section 25 (made of 2219-T8 aluminum alloy) after rolling and bending, which is 3800 mm, the distance between the first support roller 5 and the second support roller 6 needs to be set to an appropriate size (500 mm). The first moving drive servo motor drives the first support roller 5 and the second support roller 6 to move to the specified position. Step 2: Place a 11948mm long ribbed flat plate (with a process margin of 8mm in width and 5mm in thickness at both ends of the length) on the feed wheel group 2 of the device, and push the ribbed flat plate blank to feed so that its end moves between the active roller 4 and the first and second support rollers 5 and 6, and the non-ribbed surface (processing surface) just contacts the support roller surfaces of the first and second support rollers 5 and 6; Step 3: The second mobile drive servo motor 17 is controlled by the numerical control system. The second mobile drive servo motor 17 drives the active roller 4 to realize the movement of the active roller 4 toward the middle of the first support roller 5 and the second support roller 6. After just contacting the ribbed surface of the flat sheet, the active roller 4 continues to be fed forward 62 mm to realize the press bending of the end of the flat sheet. Then, the rotary drive servo motor 7 is controlled by the numerical control system to drive the first support roller 5 and the second support roller 6 to rotate, and the flat sheet is gradually rolled into a cylindrical section with a diameter of 3800 mm. After rolling, the total width of the process margin at the joint of the cylindrical section 25 is 16 mm. Step 4: The second mobile drive servo motor 17 is controlled by the numerical control system. The second mobile drive servo motor 17 drives the active roller 4 to separate from the first support roller 5 and the second support roller 6, and removes the main movable side plate 4b of the active roller 4, the first movable side plate 5b of the first support roller 5, and the second movable side plate 6b of the second support roller 6, leaving the main section roller 4a, the first section roller 5a, and the second section roller 6a respectively. Then, the main section roller 4a is driven to rotate by the rotation drive servo motor 7. When the main section roller 4a rotates until the center line of the main section length direction intersects perpendicularly with the axis of the main shaft 14, it stops rotating and is locked; Step 5: Drive the first cross-section roller 5a and the second cross-section roller 6a to rotate by rotating the servo motor 7 respectively, and stop rotating and lock when the first cross-section roller 5a and the second cross-section roller 6a are parallel to the main cross-section respectively, and the other first cross-section roller 5a and the other second cross-section roller 6a are parallel to each other, and then drive the first cross-section roller 5a and the second cross-section roller 6a to move linearly by the first moving servo motor 9, and stop moving and lock when the distance between the first cross-section and the second cross-section of the first cross-section roller 5a and the second cross-section roller 6a is 50mm.

[0040] Step 6: Drive the main cross-section roller 4a to move towards the first cross-section roller 5a and the second cross-section roller 6a by the second moving servo motor 17, so as to clamp the joint part of the cylinder segment 25, as shown in Figure 4

[0041] Step 7: Install a diamond milling cutter 23 with a diameter of 16mm on the main shaft 14, and drive the second sliding block 22 to move by the second moving servo motor 17, so as to drive the main shaft 14 to feed, at the same time, drive the third sliding block 21 to move upward by the third moving servo motor 19, so as to make the diamond milling cutter 23 close to the process excess edge of the joint part of the cylinder segment 25.

[0042] Step 8: Control the main shaft 14 to drive the diamond milling cutter 23 to rotate at a speed of 3000r / min by using the numerical control system, and drive the third sliding block 21 to move linearly downward at a speed of 600mm / min by the third moving servo motor 19, so as to drive the diamond milling cutter 23 to mill the process excess edge in one pass with a cutting depth of 2mm, then the main shaft 14 feeds forward by 2mm, and the third sliding block 21 moves upward to complete the second pass of milling the process excess edge, then the main shaft 14 feeds forward by 2mm again, and the third sliding block 21 moves downward to complete the third pass of milling the process excess edge, so as to completely mill and remove the process excess edge with a thickness of 5mm; Step 9: Control the main cross-section roller 4a, the first cross-section roller 5a and the second cross-section roller 6a to separate from the joint part of the cylinder segment 25 by the numerical control system, then manually joint the joint part of the cylinder segment 25, and then control the main cross-section roller 4a, the first cross-section roller 5a and the second cross-section roller 6a to feed to the joint part again, so as to clamp the joint part again; ​Step 10: install the friction stir welding heat-resistant die steel stir head 24 on the main shaft 14, and drive the second sliding block 22 to move by the second movement driving servo motor 17, drive the main shaft 14 to feed, at the same time, drive the third sliding block 21 to move upward by the third movement driving servo motor 19, and then make the heat-resistant die steel stir head 24 close to the upper part of the joint part of the cylinder segment 25, at a distance of 1.0mm from the outer surface of the cylinder segment; Step 11: use the numerical control system to control the main shaft 14 to drive the heat-resistant die steel stir head 24 to rotate at a speed of 1500r / min and to feed forward by 5.8mm by the second sliding block 22, then drive the third sliding block 21 to move downward at a speed of 200mm / min by the third movement driving servo motor 19, drive the heat-resistant die steel stir head 24 to longitudinally friction stir weld the joint part of the cylinder segment 25. Step 12: control the driving roller 4, the first supporting roller 5 and the second supporting roller 6 to separate from the joint part of the cylinder segment 25 by the numerical control system, and obtain the target cylinder segment 25 product.

[0043] The manufacturing method can realize the integral forming of the large-scale storage tank cylinder segment by taking an ultra-long plate as a slab, the cylinder segment has only one weld, compared with the cylinder segment made of 4-5 small slabs, the number of welds is greatly reduced, the structural reliability is significantly improved, and the welding process is greatly shortened.

[0044] The manufacturing method can solve the influence of the changed gravity moment caused by the gravity center movement of the plate during the roll bending process on the roll bending deformation by adopting the vertical roll bending process instead of the traditional horizontal roll bending process, improve the manufacturing precision of the cylinder segment, and the curvature of the outer shape of the roll-bent cylinder segment can be accurately measured on the machine, without the need of placing the cylinder segment vertically after the roll bending and then measuring, so that the roll bending deformation can be detected and adjusted in situ, and the problem of repeated roll bending on the machine and detection after the roll bending is solved, and the operation is complicated and time-consuming.

[0045] Those skilled in the art know that, in addition to implementing the system and each device, module and unit thereof provided by the present application in the form of pure computer readable program code, the same functions can also be realized by logically programming the method steps in the form of logic gates, switches, application specific integrated circuits, programmable logic controllers and embedded microcontrollers. Therefore, the system and each device, module and unit thereof provided by the present application can be considered as a hardware component, and the devices, modules and units included therein for realizing various functions can also be considered as structures in the hardware component; the devices, modules and units for realizing various functions can also be considered as both software modules and structures in the hardware component.

[0046] In the description of this application, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0047] The above describes specific embodiments of the present invention. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art may make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. The embodiments of this application and the features in the embodiments may be combined with each other in any manner unless there is a conflict.

Claims

1. A large tank segment vertical milling and welding integrated manufacturing device, characterized in that: It comprises an active roller (4), a first supporting roller (5), a second supporting roller (6), a main shaft (14), a rotary drive assembly, a first moving assembly, a second moving assembly, and a third moving assembly; The first moving assembly drives the first supporting roller (5) and the second supporting roller (6) to perform linear reciprocating motion in the first direction, the second moving assembly drives the active roller (4) and the third moving assembly to perform linear reciprocating motion in the second direction, and the third moving assembly drives the main shaft (14) to perform linear reciprocating motion in the third direction; The first direction, the second direction and the third direction are perpendicular to each other; The first support roller (5) and the second support roller (6) are both arranged between the active roller (4) and the main shaft (14); The rotary drive assembly drives the active roller (4), the first support roller (5) and the second support roller (6) to perform rotational motion respectively; A milling cutter or a stirring head is provided on the main shaft (14).

2. The large tank barrel segment vertical milling and welding integrated manufacturing device according to claim 1 is characterized in that: The active roller (4) comprises a main section roller (4a) and a main movable side plate (4b), the main section roller (4a) comprises a main section, and the main section roller (4a) is matched with the main movable side plate (4b) to form a circular roller state; The first support roller (5) comprises a first section roller (5a) and a first movable side plate (5b), the first section roller (5a) comprises a first section, and the first section roller (5a) is matched with the first movable side plate (5b) to form a circular roller state through the first section; The first sections include two sections, which are perpendicular to each other and arranged on the same line; The second support roller (6) comprises a second section roller (6a) and a second movable side plate (6b), the second section roller (6a) comprises a second section, and the second section roller (6a) is matched with the second movable side plate (6b) through the second section to form a circular roller state; The second sections include two sections, which are perpendicular to each other and arranged on the same line.

3. The large tank barrel segment vertical milling and welding integrated manufacturing device according to claim 2 is characterized in that: A square groove is opened in the middle of the main section, and the length of the square groove is the same as the length of the main section.

4. The large tank barrel segment vertical rolling milling and welding integrated manufacturing device according to claim 1 is characterized in that: The spindle (14) rotates to drive the milling cutter or the stirring head to work; When a milling cutter is provided on the spindle (14), the device comprises a milling processing module; When a stirring head is provided on the main shaft (14), the device comprises a friction stir welding module.

5. The large tank barrel segment vertical milling and welding integrated manufacturing device according to claim 1 is characterized in that: The machine also includes a frame (1), the frame (1) including an upper base plate and a lower base plate, and at least one set of a first moving assembly, a second moving assembly, and a third moving assembly are respectively arranged on the upper base plate and the lower base plate; The upper end and / or lower end of the first supporting roller (5) is connected to the first moving component; The upper end and / or lower end of the second supporting roller (6) is connected to the first moving component; The upper end and / or lower end of the active roller (4) is connected to the second moving component; The upper end and / or the lower end of the third moving component is connected to the second moving component.

6. The large tank barrel segment vertical rolling milling and welding integrated manufacturing device according to claim 5 is characterized in that: The upper base plate includes a first upper base plate and a second upper base plate. The distance between the first upper base plate and the lower base plate is equal to the distance between the second upper base plate and the lower base plate. The first upper base plate and the second upper base plate are connected by a gap, and the gap allows the barrel section to pass through.

7. The large tank barrel segment vertical rolling milling and welding integrated manufacturing device according to claim 1 is characterized in that: The first moving assembly comprises a first lead screw (11), a first slider (12) and a first moving drive servo motor (9), wherein the first slider (12) is connected to the first lead screw (11), and the first moving drive servo motor (9) drives the first lead screw (11) to rotate, thereby driving the first slider (12) to perform linear motion; The second moving assembly includes a second lead screw (16), a second slider (22) and a second moving drive servo motor (17), wherein the second slider (22) is connected to the second lead screw (16), and the second moving drive servo motor (17) drives the second lead screw (16) to rotate, thereby driving the second slider (22) to perform linear motion; The third moving assembly includes a third lead screw (15), a third slider (21) and a third moving drive servo motor (19), wherein the third slider (21) is connected to the third lead screw (15), and the third moving drive servo motor (19) drives the third lead screw (15) to rotate, thereby driving the third slider (21) to perform linear motion; The first lead screw (11) and the second lead screw (16) are arranged to intersect vertically, and the third lead screw (15) and the second lead screw (16) are arranged to intersect vertically.

8. The large tank barrel segment vertical rolling milling and welding integrated manufacturing device according to claim 1 is characterized in that: The rotary drive assembly includes a rotary drive servo motor (7), and the rotary drive servo motor (7) includes three groups. The three groups of rotary drive servo motors (7) respectively drive the active roller (4), the first support roller (5), and the second support roller (6) to perform rotary motion.

9. The large tank barrel segment vertical rolling milling and welding integrated manufacturing device according to claim 1, characterized in that: It also includes a feed wheel group (2) and a discharge wheel group (3), wherein the feed wheel group (2) includes a plurality of feed rollers arranged parallel to each other, and the discharge wheel group (3) includes a plurality of discharge rollers arranged in an arc shape.

10. A method for manufacturing large tank segments by vertical milling and welding, characterized in that: The large tank barrel segment vertical rolling milling and welding integrated manufacturing device according to any one of claims 1 to 9 comprises the following steps: Step S1: Preset stage: according to the preset diameter of the barrel section after rolling, the spacing between the first support roller (5) and the second support roller (6) is set and the first support roller (5) and the second support roller (6) are driven to the set position; Step S2: Roll forming stage: Step S2.1: pushing one end of the flat sheet in an upright state between the active roller (4) and the first support roller (5) and the second support roller (6), so that the processed surface of the flat sheet contacts the surfaces of the first support roller (5) and the second support roller (6); Step S2.2: Control the active roller (4) to move toward the middle of the first support roller (5) and the second support roller (6) to bend the end portion of the flat sheet; Step S2.3: driving the first support roller (5) and the second support roller (6) to rotate, gradually rolling the flat blank into a cylindrical section (25) of a preset diameter; Step S3 transition phase: Step S3.1: driving the active roller (4) to separate from the first support roller (5) and the second support roller (6), removing the main movable side plate (4b), the first movable side plate (5b) and the second movable side plate (6b), leaving the main section roller (4a), the first section roller (5a) and the second section roller (6a); Step S3.2: driving the main section roller (4a) to rotate until the center line of the main section in the longitudinal direction intersects perpendicularly with the axis of the main shaft (14), and driving the first section roller (5a) and the second section roller (6a) to rotate until one of the first sections of the first section roller (5a) and one of the second sections of the second section roller (6a) are parallel to the main section and the other first section of the first section roller (5a) and the other second section of the second section roller (6a) are parallel to each other; Step S4: milling process: Step S4.1: driving the main section roller (4a) to move toward the first section roller (5a) and the second section roller (6a) to clamp the closing section of the barrel section (25); Step S4.2: Install a milling cutter on the main shaft (14), and drive the main shaft (14) to move to the process margin near the joint of the barrel section (25); Step S4.3: driving the spindle (14) to rotate and move the spindle (14) up and down, so that the milling cutter performs milling processing on the process edge at a set cutting depth until the process edge is removed; Step S5: Friction stir welding stage: Step S5.1: Control the main section roller (4a), the first section roller (5a), and the second section roller (6a) to separate from the barrel section closing section, manually close the barrel section closing section, and control the main section roller (4a), the first section roller (5a), and the second section roller (6a) to feed toward the barrel section closing section again, so as to re-clamp the barrel section (25); Step S5.2: Install a stirring head on the main shaft (14), and drive the main shaft (14) until the stirring head is close to the upper part of the joint of the barrel section and close to the outer surface of the barrel section (25); Step S5.3: Control the main shaft (14) to rotate and drive the main shaft (14) to move forward a set distance, and drive the main shaft (14) to move downward to achieve longitudinal friction stir welding of the joint of the barrel section (25) by the stirring head.

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