Integrated vertical roll milling and welding manufacturing equipment and method for large storage tank sections

Abstract

This invention provides a vertical roll milling and welding integrated manufacturing device and method for large storage tank sections, comprising a drive 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 and second support rollers to reciprocate linearly in a first direction, the second moving assembly drives the drive roller and the third moving assembly to reciprocate linearly in a second direction, and the third moving assembly drives the main shaft to reciprocate linearly in a third direction. The first, second, and third directions are perpendicular to each other. The first and second support rollers are both disposed between the drive roller and the main shaft. The rotary drive assembly drives the drive roller, the first support roller, and the second support roller to rotate. A milling cutter or a stirring head is mounted on the main shaft.

Description

Technical Field

[0001] This invention relates to the field of metal plastic forming technology, specifically to a vertical roll milling and welding integrated manufacturing apparatus and method for large storage tank sections. Background Technology

[0002] In recent years, the global space program has entered a new phase characterized by large-scale constellation deployment and the development and utilization of space resources. High-density launches of carrier rockets have become the new normal. How to improve rocket manufacturing efficiency and reduce manufacturing costs while ensuring rocket manufacturing quality has become a key concern for major spacefaring nations. Large propellant tanks are crucial structural components and major load-bearing parts of carrier rockets, responsible for storing the rocket's launch fuel. Their manufacturing quality directly impacts the reliability and safety of the carrier rocket's flight, while their manufacturing efficiency and cost have a significant influence on the overall rocket manufacturing cycle and cost control.

[0003] The cylindrical section is one of the two main components of the propellant tank. It primarily forms the cylindrical shape of the tank and bears the axial compressive load of the rocket body and the internal pressure of the tank during flight. Currently, the cylindrical section is mainly manufactured by welding 4-5 curved wall panels together circumferentially, involving the welding of 4-5 longitudinal seams. The curved wall panels are typically manufactured by roll bending from a flat surface to a curved surface, followed by edge milling before welding.

[0004] A Chinese patent application with publication number CN118635325A discloses a system and method for precise bending and forming a large thin-walled storage tank section, relating to the field of metal plastic forming technology. This invention solves the problem of precise bending and forming of a large thin-walled storage tank section. Specifically, it includes: firstly, constructing a rolling bending fixture mainly composed of an electric feeding platform, axial limiting devices, and radial auxiliary supports. During the rolling bending process of the ultra-long wall panel, guide rollers on the axial limiting devices on both sides clamp the two sides of the ultra-long wall panel, ensuring that the ultra-long wall panel remains clamped throughout the rolling bending process, preventing lateral slippage and eliminating misalignment after closure. This patent application uses one ultra-long wall panel instead of the traditional 4-5 small wall panels, and uses a horizontal rolling bending machine to integrally roll and bend the ultra-long wall panel into an open section. Subsequent welding with only one longitudinal seam is required to obtain the closed section product, significantly reducing the number of welds, improving the structural reliability of the section, and shortening the manufacturing process. The main problem is that when the ultra-long wall panel is rolled horizontally, it is in a flat state. Due to its own weight, the curvature of the outer surface formed by the roll is difficult to be accurately detected on the machine. The rolled section must be lifted off the machine and placed vertically for measurement. Once the dimensional deviation is found, it can only be rolled again. This process is repeated, which is very time-consuming. In addition, side support and top support devices must be configured. During the forming process, the side support force and top support force are constantly adjusted to counteract the influence of changing gravitational torque, making the operation process complicated.

[0005] A Chinese patent application with publication number CN114798842A discloses a CNC four-axis vertical roll bending forming equipment, relating to the field of plate roll bending equipment. It includes an upper frame connected to left and right connecting beams and fixedly mounted on a chassis. The front, rear, left, and right axes are parallel to each other and perpendicular to the chassis, respectively mounted on the upper and lower frames. Bearings are installed at both ends of the front axis and fixedly mounted on the upper and lower frames via the bearings. This patent application uses a vertical feeding method, and the forming process is largely unaffected by the weight of the plate, requiring no additional material support. It can accurately measure the roll bending rate on-machine, making operation very convenient. However, when used for forming tank sections, after the vertical roll bending of the section is completed, the resulting open section still needs to be transferred to a milling machine for edge milling, and then transported to a welding machine for joint welding. The entire process remains very cumbersome.

[0006] The existing technology for manufacturing cylindrical sections requires the bending, milling, and welding processes to be carried out on three completely different specialized processing devices. This involves the transfer and placement of 4-5 wall panels between different devices, which takes a significant amount of time. Furthermore, cylindrical sections manufactured using this method have many weak weld areas, resulting in low manufacturing efficiency and making it difficult to meet the requirements for high-quality and high-efficiency production of subsequent cylindrical sections. Summary of the Invention

[0007] To address the shortcomings of existing technologies, the purpose of this invention is to provide an integrated manufacturing device and method for vertical roll milling and welding of large storage tank sections.

[0008] According to the present invention, a vertical roll milling and welding integrated manufacturing device for large storage tank sections is provided, comprising an active 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;

[0009] The first moving component drives the first support roller and the second support roller to perform linear reciprocating motion in the first direction, the second moving component drives the drive roller and the third moving component to perform linear reciprocating motion in the second direction, and the third moving component drives the main shaft to perform linear reciprocating motion in the third direction.

[0010] The first direction, the second direction, and the third direction are perpendicular to each other;

[0011] Both the first support roller and the second support roller are disposed between the drive roller and the main shaft;

[0012] The rotary drive assembly drives the active roller, the first support roller, and the second support roller to rotate.

[0013] Preferably, the driving roller includes a main section roller and a main movable side plate. The main section roller includes a main section, and the main section roller is matched with the main movable side plate to form a circular roller state.

[0014] The first support 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 matches the first movable side plate to form a circular roller state.

[0015] The first cross-section includes two sections, which are perpendicular to each other and collinear.

[0016] The second support 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 matches the second movable side plate to form a circular roller state.

[0017] The second section comprises two sections, which are perpendicular to each other and collinear.

[0018] Preferably, a square groove is formed in the middle of the main cross-section, and the length of the square groove is the same as the length of the main cross-section.

[0019] Preferably, the main shaft is provided with a milling cutter or a stirring head, and the rotation of the main shaft drives the milling cutter or stirring head to work;

[0020] When a milling cutter is mounted on the spindle, the device includes a milling module;

[0021] When a stirring head is installed on the spindle, the device includes a friction stir welding module.

[0022] Preferably, it also includes a frame, the frame including an upper base plate and a lower base plate, and at least one set of a first moving component, a second moving component and a third moving component are respectively provided on the upper base plate and / or the lower base plate;

[0023] The upper end and / or lower end of the first support roller is connected to the first moving component;

[0024] The upper end and / or lower end of the second support roller are connected to the first moving component;

[0025] The upper and / or lower ends of the active roller are connected to the second moving component;

[0026] The upper and / or lower ends of the third moving component are connected to the second moving component.

[0027] 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, and the first upper base plate and the second upper base plate are connected by a gap, the gap allowing the cylinder section to pass through.

[0028] Preferably, the first moving component 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 causing the first slider to move in a straight line.

[0029] The second moving component 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, and the second moving drive servo motor drives the second lead screw to rotate, thereby causing the second slider to move in a straight line.

[0030] The third moving component 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, and the third moving drive servo motor drives the third lead screw to rotate, thereby causing the third slider to move in a straight line.

[0031] The first lead screw and the second lead screw are arranged perpendicularly to each other, and the third lead screw is arranged perpendicularly to the second lead screw.

[0032] Preferably, the rotary drive assembly includes a rotary drive servo motor, and the rotary drive servo motor includes three sets, which respectively drive the active roller, the first support roller and the second support roller to rotate.

[0033] Preferably, it further includes a feed roller assembly and a discharge roller assembly, wherein the feed roller assembly includes a plurality of feed rollers arranged in parallel to each other, and the discharge roller assembly includes a plurality of discharge rollers arranged in an arc shape.

[0034] This invention also provides a method for the integrated vertical roll milling and welding manufacturing of large storage tank sections, comprising the following steps:

[0035] Step S1 Preset Stage: Based on the preset diameter of the cylinder section after bending, set the distance between the first support roller and the second support roller and drive the first support roller and the second support roller to the set position;

[0036] Step S2: Roll forming stage

[0037] Step S2.1: Push one end of the vertically positioned flat blank between the drive roller and the first support roller and the second support roller, so that the processing surface of the flat blank contacts the surface of the first support roller and the second support roller;

[0038] Step S2.2: Control the active roller to move towards the middle of the first support roller and the second support roller to bend the end of the flat blank.

[0039] Step S2.3: Drive the first support roller and the second support roller to rotate, and gradually roll the flat blank into a cylindrical section of a preset diameter;

[0040] Step S3 Transition Phase:

[0041] Step S3.1: Drive the active roller to separate 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;

[0042] Step S3.2: Drive the main section roller to rotate until the center line of the main section length direction intersects perpendicularly with the axis of the main shaft. Drive 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 each other.

[0043] Step S4 Milling stage:

[0044] Step S4.1: Drive the main section roller to move towards the first section roller and the second section roller to clamp the joint of the cylinder section;

[0045] Step S4.2: Install the milling cutter on the spindle and drive the spindle to move to the process margin near the joint of the cylinder section;

[0046] Step S4.3: Drive the spindle to rotate and move the spindle up and down to achieve milling of the process excess edge by the milling cutter at the set depth of cut until the process excess edge is removed;

[0047] Step S5: Friction Stir Welding Stage

[0048] Step S5.1: Control the main section roller, the first section roller, and the second section roller to separate from the joint of the cylinder section, manually close the joint of the cylinder section, and control the main section roller, the first section roller, and the second section roller to feed back to the joint of the cylinder section to achieve re-clamping of the joint of the cylinder section.

[0049] Step S5.2: Install the stirring head on the main shaft and drive the main shaft to move until the stirring head is close to the upper part of the confluence of the cylinder section and near the outer surface of the cylinder section;

[0050] Step S5.3: Control the main shaft to rotate and drive the main shaft to move forward a set distance. Drive the main shaft to move downward to achieve longitudinal stirring friction welding of the cylinder section joint by the stirring head.

[0051] Compared with the prior art, the present invention has the following beneficial effects:

[0052] 1. The manufacturing device of the present invention integrates the three major functions of cylinder section bending, milling and welding into one, so that the process that originally needed to be carried out on three different special processing devices can be completed on one device, which greatly reduces the workload of material transfer and loading between different devices, significantly improves manufacturing efficiency and reduces manufacturing costs.

[0053] 2. The manufacturing apparatus of the present invention sets the active roller, the first support roller and the second support roller to two states: one is a circular roller state, in which the rolling bending of the cylinder segment is realized, and the other is a cross-section roller state, in which the edge milling and welding of the cylinder segment are realized, thereby improving manufacturing efficiency.

[0054] 3. The manufacturing apparatus of the present invention provides a square groove on the main cross-section, which can avoid the milling cutter or stirring head on the one hand, and use the square groove to position the main cross-section roller, thereby achieving the positional matching between the main cross-section roller and the main shaft, which is beneficial for precise milling and welding of cylinder sections.

[0055] 4. The manufacturing method of the present invention can realize the integral forming of large storage tank sections by using an ultra-long plate as a blank. The manufactured section has only one weld. Compared with the conventional section made by welding 4 to 5 small plates, the number of welds in the section is greatly reduced, the structural reliability is significantly improved, and the assembly and welding process is greatly shortened.

[0056] 5. The manufacturing method of this invention replaces the traditional horizontal rolling bending process with a vertical rolling bending process, which can solve the problem of the influence of the changing gravitational torque caused by the shift 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 bending section can be accurately measured in the machine without having to place it vertically after removing it from the machine for measurement. Therefore, it can realize in-situ detection of rolling deformation and in-situ adjustment of rolling bending process parameters, which solves the problem of repeated rolling and inspection required when using a horizontal rolling bending machine, which is cumbersome and time-consuming. Attached Figure Description

[0057] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0058] Figure 1 This mainly illustrates the structural diagram of the manufacturing apparatus of the present invention;

[0059] Figure 2 This mainly illustrates the structural diagram of the manufacturing apparatus of the present invention;

[0060] Figure 3 The exploded view mainly illustrates the active roller, the first support roller, and the second support roller of the present invention;

[0061] Figure 4This diagram mainly illustrates the clamping of the joint of the roll-bending forming cylinder section by the active roller and the support roller of the present invention.

[0062] Figure 5 This invention mainly illustrates the roll bending forming of the storage tank section.

[0063] Figure 6 This diagram mainly illustrates the process of milling the excess edge of the tank section and welding the joint area according to the present invention.

[0064] Figure 7 The main diagram illustrates the principle of the present invention for milling the excess edge of the storage tank section;

[0065] Figure 8 The main diagram illustrates the principle of friction stir welding at the joint of the storage tank section in this invention.

[0066] As shown in the figure:

[0067] Detailed Implementation

[0068] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0069] The present invention provides a vertical roll milling and welding integrated manufacturing device for large storage tank sections, comprising a frame 1, a feeding roller group 2, a discharging roller group 3, a drive roller 4, a first support roller 5, a second support roller 6, multiple rotary drive servo motors 7, multiple rotary drive reducers 8, multiple motion drive servo motors, multiple motion drive reducers, multiple lead screws, multiple sliders, a main spindle 14, and a control cabinet 13, among other core components. The control cabinet 13 is equipped with a CNC system, which controls the use of the drive roller 4, the first support roller 5, the second support roller 6, and the main spindle 14 in different states. The manufacturing device of the present invention forms three major processing modules: a vertical CNC three-axis roll bending forming module, a milling processing module, and a friction stir welding module.

[0070] Specifically, such as Figure 1 and Figure 2As shown, the manufacturing apparatus of the present invention includes a drive roller 4, a first support roller 5, a second support 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 support roller 5 and the second support roller 6 to perform linear reciprocating motion in a first direction. The second moving assembly drives the drive roller 4 and the third moving assembly to perform linear reciprocating motion in a second direction. The third moving assembly drives the main shaft 14 to perform linear reciprocating motion in a 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 disposed between the drive roller 4 and the main shaft 14. The rotary drive assembly drives the drive roller 4, the first support roller 5, and the second support roller 6 to perform rotational motion.

[0071] A three-dimensional coordinate system can be formed by the first direction, the second direction, and the third direction. 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 moving component in the first direction and the second moving 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 set or symmetrically moved relative to the origin. The active roller 4 and the third moving component can be symmetrically set or symmetrically moved relative to the origin. The cylinder segment also passes through this origin after entering the device.

[0072] Specifically, such as Figure 3 and Figure 4 As shown, the driving roller 4 includes a main section roller 4a and a main movable side plate 4b. The main section roller 4a includes a main section, and the main section roller 4a matches the main movable side plate 4b to form a circular roller state. The first support roller 5 includes a first section roller 5a and a first movable side plate 5b. The first section roller 5a includes a first section, and the first section roller 5a matches the first movable side plate 5b to form a circular roller state. The first section includes two sections, which are perpendicular to each other and collinearly arranged. The second support roller 6 includes a second section roller 6a and a second movable side plate 6b. The second section roller 6a includes a second section, and the second section roller 6a matches the second movable side plate 6b to form a circular roller state. The second section includes two sections, which are perpendicular to each other and collinearly arranged.

[0073] Specifically, the first moving assembly includes a first lead screw 11, a first slider 12, a first moving drive servo motor 9, and a first moving drive reducer 10. The first slider 12 has a threaded hole in its center and is connected to the first lead screw 11 via a thread. The first moving drive servo motor 9 and the first moving drive reducer 10 drive the first lead screw 11 to rotate, thereby driving the first slider 12 to move linearly. The second moving assembly includes a second lead screw 16, a second slider 22, a second moving drive servo motor 17, and a second moving drive reducer 18. The second slider 22 has a threaded hole in its center and is connected to the second lead screw 16 via a thread. The second moving drive servo motor 17 and the second moving drive reducer 18 drive the second lead screw 16 to rotate, thereby driving the second slider 22 to move linearly. The third moving component includes a third lead screw 15, a third slider 21, a third moving drive servo motor 19, and a third moving drive reducer 20. The third slider 21 has a threaded hole in its center and is connected to the third lead screw 15 by threads. The third moving drive servo motor 19 and the third moving drive reducer 20 drive the third lead screw 15 to rotate, thereby driving the third slider 21 to move linearly. The first lead screw 11 and the second lead screw 16 are arranged perpendicularly to each other, and the third lead screw 15 and the second lead screw 16 are also arranged perpendicularly to each other.

[0074] In this system, a mobile drive servo motor and a mobile drive reducer are used together. The servo motor generally rotates at a very high speed. After being reduced in speed by the reducer, the torque of the servo motor can be amplified, and the speed will not be too fast. This will drive the lead screw to rotate at a relatively low speed. After the lead screw rotates, it transmits force through the thread, driving the slider connected to it to move linearly.

[0075] One feasible implementation is as follows: The frame 1 includes an upper base plate and a lower base plate. At least one set of first moving components, a second moving component, and a third moving component are respectively provided on the upper base plate and / or the lower base plate. The upper end and / or lower end of the first support roller 5 are connected to the first moving component, the upper end and / or lower end of the second support roller 6 are connected to the first moving component, the upper end and / or lower end of the drive roller 4 are connected to the second moving component, and the upper end and / or lower end of the third moving component are connected to the second moving component. Alternatively, one set of first moving components, one set of second moving components, and one set of third moving components can be uniformly provided 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 moving component, and the upper ends of the drive roller 4 and the third lead screw 15 are respectively connected to one set of second moving components. Alternatively, one set of first moving components, one set of second moving components, and one set of third moving components can be uniformly provided on the lower base plate, with a similar arrangement. Preferably, a first set of moving components, a second set of moving components, and a third set of moving components are symmetrically arranged on the upper base plate and the lower base plate. The upper and lower ends of the first support roller 5 and the second support roller 6 are respectively connected to the first moving components, and the upper and lower ends of the drive roller 4 and the third moving components are respectively connected to the second moving components.

[0076] 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 to the distance between the second upper base plate and the lower base plate, and both are at the same height. The first upper base plate and the second upper base plate are connected with a gap, which allows the cylindrical section 25 to pass through. The first upper base plate and the second upper base plate are connected to the lower base plate through 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 ends of the first upper base plate and the second upper base plate are not connected, forming a certain gap between them. This gap allows the cylindrical section 25 to be removed between the upper base plate and the lower base plate.

[0077] The feeding roller assembly 2 of this manufacturing apparatus includes multiple feeding rollers arranged in parallel to each other, which are installed at the front of the frame. The discharging roller assembly 3 includes multiple discharging rollers arranged in an arc shape on the left side of the frame.

[0078] like Figure 5 As shown, the CNC three-axis roll bending forming module includes an active roller 4, a first support roller 5, and a second support roller 6. All three are driven to rotate by independent rotary drive servo motors 7 and rotary drive reducers 8. The active roller 4, first support roller 5, and second support roller 6 are also driven to move linearly by independent motion drive servo motors and motion drive reducers. Through the linear and rotary movements of the three rollers, a flat blank can be rolled into a cylindrical section. Specifically, the first support roller 5 and second support roller 6 are each driven to move linearly by a corresponding first motion component. The first motion drive servo motor 9 drives the first slider 12 to move linearly. The first support roller 5 and second support roller 6 are respectively mounted on the first slider 12. Movement of the first slider 12 drives the first support roller 5 and second support roller 6 to move linearly. The active roller 4 is driven to move linearly by a second motion component. The second motion drive servo motor 17 drives the second slider 22 to move. The active roller 4 and the third motion component are both mounted on the second slider 22. Movement of the second slider 22 drives the active roller 4 and the third motion component to move linearly. The first motion drive servo motor 9 and the second motion drive servo motor 17 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 drive roller 4 to move closer or further apart from each other.

[0079] Preferably, the active roller 4 has a diameter of 400mm and a length of 2000mm, while the first support roller 5 and the second support roller 6 both have a diameter of 200mm and a length of 2000mm. The active roller 4 includes a main section roller 4a and a main movable side plate 4b with a width of 150mm. The first support roller 5 includes a first section roller 5a and two first movable side plates 5b with a width of 150mm. The second support roller 6 includes a second section roller 6a and two second movable side plates 6b. The main movable side plate 4b, the first movable side plate 5b, and the second movable side plate 6b all have countersunk holes, which can be connected to the main section roller 4a, the first section roller 5a, and the second section roller 6a respectively by three M10 screws to form a complete circular roller. The two first sections of the first section roller 5a are perpendicular to each other and collinear, and the two second sections of the second section roller 6a are perpendicular to each other and collinear.

[0080] like Figures 6 to 8 As shown, the milling module and the friction stir welding module share a set of core components such as control cabinet 13, spindle 14, lead screw, motion drive servo motor, motion drive reducer, and slider.

[0081] The spindle 14 rotates at speeds ranging from 1000 r / min to 3000 r / min. When a diamond end mill 23 is mounted on the spindle 14, it, along 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, forms a milling module. Figure 7 As shown, the main section roller 4a, the first section roller 5a, and the second section roller 6a are driven to move in a straight line and come closer to each other by the second moving component and the first moving component, respectively, to clamp the joint of the roll-bent cylindrical section 25. Then, the diamond end mill 23 rotating at high speed on the spindle 14 is driven by the second moving component to move to the top of the process excess edge of the joint. After that, the spindle 14 is controlled to move downward by the third moving component to remove the process excess edge by milling.

[0082] When the friction stir welding heat-resistant mold 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 main section roller 4a, the first section roller 5a, and the second section roller 6a are driven to move in a straight line and come closer to each other by the second moving component and the first moving component, respectively, to clamp the joint of the milled cylinder section 25. Then, the rotating stirring head 24 on the main shaft 14 is driven to move to the upper part of the joint by the second moving component. After that, the main shaft 14 is controlled to move downward by the third moving component to achieve longitudinal welding of the joint, welding the open cylinder section into a closed cylinder section 25.

[0083] The main section of the main section roller 4a of the drive roller 4 has a rectangular groove of the same length as the drive roller 4. The position of the main section roller 4a is determined by the perpendicular intersection of the center line of the rectangular groove with the axis of the main shaft, thus achieving a positional fit between the main section roller 4a and the main shaft 14, thereby enabling more precise milling and welding of the cylinder section 25. Preferably, the rectangular groove has a width of 30mm, a depth of 30mm, and a length of 2000mm. The depth of the rectangular groove meets the requirement that the main section roller 4a avoids the milling cutter or stirring head.

[0084] The manufacturing apparatus of this invention integrates a CNC three-axis roll bending module, a milling module, and a friction stir welding module. The milling module and the friction stir welding module share a single spindle, which can be used to mount both milling cutters and a stirring head. When manufacturing cylindrical sections using this apparatus, a flat blank with process excess edges in a vertical position is first roll-bent into a cylindrical shape using three axes. Then, the milling module removes the process excess edges at the joint of the roll bend. Finally, the friction stir welding module longitudinally welds the joint, completing the cylindrical section manufacturing process. This invention uses a single device to complete the cylindrical section manufacturing process that typically requires three devices, significantly reducing the workload of transferring materials between different devices. The fully vertical processing method significantly improves the manufacturing efficiency and accuracy of the cylindrical sections.

[0085] This invention also provides a highly efficient manufacturing method for vertical roll milling and welding of large storage tank sections, comprising the following steps:

[0086] Step S1 Preset Stage: Based on the preset diameter of the cylinder section 25 after rolling, set the distance between the first support roller 5 and the second support roller 6 and drive the first support roller 5 and the second support roller 6 to the set position;

[0087] Step S2: Roll forming stage

[0088] Step S2.1: Push one end of the vertically positioned flat blank between the drive roller 4 and the first support roller 5 and the second support roller 6, so that the processing surface of the flat blank contacts the surface of the first support roller 5 and the second support roller 6;

[0089] Step S2.2: Control the active roller to move towards the middle of the first support roller 5 and the second support roller 6 to bend the end of the flat blank.

[0090] Step S2.3: Drive the first support roller 5 and the second support roller 6 to rotate, and gradually roll the flat blank into a cylindrical section 25 of a preset diameter;

[0091] Step S3 Transition Phase:

[0092] Step S3.1: Drive the active roller 4 to separate 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, leaving the main section roller 4a, the first section roller 5a and the second section roller 6a.

[0093] Step S3.2: Drive the main section roller 4a to rotate until the center line of the main section length direction intersects perpendicularly with the axis of the main shaft 14. 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 each other.

[0094] Step S4 Milling stage:

[0095] Step S4.1: Drive the main section roller 4a to move towards the first section roller 5a and the second section roller 6a to clamp the conjoined section of the cylinder segment 25;

[0096] Step S4.2: Install a milling cutter on the spindle 14 and drive the spindle 14 to move to the process margin near the joint of the cylinder section 25;

[0097] Step S4.3: Drive the spindle 14 to rotate and move the spindle 14 up and down to realize the milling cutter to mill the process excess edge with the set cutting depth until the process excess edge is removed;

[0098] Step S5: Friction Stir Welding Stage

[0099] Step S5.1: Control the main section roller 4a, the first section roller 5a, and the second section roller 6a to separate from the joint of the cylinder section 25, manually close the joint of the cylinder section 25, and control the main section roller 4a, the first section roller 5a, and the second section roller 6a to feed back to the joint of the cylinder section 25 to achieve re-clamping of the joint of the cylinder section 25;

[0100] Step S5.2: Install the stirring head on the main shaft 14 and drive the main shaft 14 to move until the stirring head is close to the upper part of the confluence of the cylinder section 25 and near the outer surface of the cylinder section;

[0101] Step S5.3: Control the main shaft 14 to rotate and drive the main shaft 14 to move forward a set distance. By driving the main shaft 14 to move downward, the stirring head performs longitudinal stirring friction welding on the joint of the cylinder section 25.

[0102] Taking the manufacturing of a ribbed flat blank with a length of 11948mm (with process margins of 8mm width and 5mm thickness at both ends in the length direction) into a cylindrical section 25 with an outer diameter of 3800mm as an example, the specific steps of this manufacturing method are as follows:

[0103] Step 1: Connect the drive roller 4, the first support roller 5, and the second support roller 6 into a circular roller state through cross-section rollers and movable side plates. Based on the outer diameter of the cylindrical section 25 (material is 2219-T8 aluminum alloy) after rolling and bending, which is 3800mm, the distance between the first support roller 5 and the second support roller 6 needs to be set to a suitable size (500mm). Drive the first support roller 5 and the second support roller 6 to the designated position through the first motion drive servo motor.

[0104] Step 2: Place the 11948mm long ribbed flat plate (with 8mm wide and 5mm thick process margins at both ends along its length) in the vertical state onto the feed roller group 2 of the device, and push the ribbed flat plate blank to feed it, so that its end part moves between the drive roller 4 and the first support roller 5 and the second support roller 6, and the unribbed surface (processed surface) just contacts the support roller surface of the first support roller 5 and the second support roller 6;

[0105] Step 3: The second motion drive servo motor 17 is controlled by the CNC system. The second motion drive servo motor 17 drives the active roller 4, so that the active roller 4 moves towards the middle of the first support roller 5 and the second support roller 6. After it just contacts the ribbed surface of the flat blank, it continues to advance 62mm to achieve the bending of the end part of the flat blank. Then, the rotary drive servo motor 7 is controlled by the CNC system to drive the first support roller 5 and the second support roller 6 to rotate, and gradually roll the flat blank into a cylindrical section with a diameter of 3800mm. After rolling, the total width of the process margin at the joint of the cylindrical section 25 is 16mm.

[0106] Step 4: Control the second motion drive servo motor 17 through the CNC system. The second motion 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, drive the main section roller 4a to rotate through the rotation drive servo motor 7. Stop the rotation and lock the main section roller 4a when the center line of the main section length direction intersects the axis of the main shaft 14 perpendicularly.

[0107] Step 5: Drive the first section roller 5a and the second section roller 6a to rotate using the rotary drive servo motor 7. Stop rotating and lock the rollers when 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 is parallel to the other second section of the second section roller 6a. Then, drive the first section roller 5a and the second section roller 6a to move linearly using the first motion drive servo motor 9. Stop moving and lock the rollers when the distance between the first and second sections of the first section roller 5a and the second section roller 6a reaches 50mm.

[0108] Step 6: The second motion drive servo motor 17 drives the main section roller 4a to move towards the first section roller 5a and the second section roller 6a, thereby clamping the joint of the cylinder section 25. Figure 4 As shown.

[0109] Step 7: Install a 16mm diameter diamond end mill 23 on the spindle 14, and drive the second slider 22 to move through the second motion drive servo motor 17 to feed the spindle 14. At the same time, drive the third slider 21 to move upward through the third motion drive servo motor 19, so that the diamond end mill 23 is close to the process margin of the joint of the cylinder section 25.

[0110] Step 8: Using the CNC system, the spindle 14 is controlled to rotate the diamond end mill 23 at a speed of 3000 r / min. The third slide 21 is driven to move linearly downward at a speed of 600 mm / min by the third motion drive servo motor 19. This drives the diamond end mill 23 to perform a first milling operation on the process edge with a depth of cut of 2 mm. After that, the spindle 14 is fed forward by 2 mm and moves upward with the third slide 21 to complete the second milling operation on the process edge. Then, the spindle 14 is fed forward by 2 mm again and moves downward with the third slide 21 to complete the third milling operation on the process edge, completely removing the 5 mm thick process edge.

[0111] Step 9: Control the main section roller 4a, the first section roller 5a, and the second section roller 6a to separate from the joint of the cylinder section 25 using the CNC system. Then, manually close the joint of the cylinder section 25. Next, control the main section roller 4a, the first section roller 5a, and the second section roller 6a to feed back to the joint to achieve re-clamping of the joint.

[0112] Step 10: Install the friction stir welding heat-resistant mold steel stirring head 24 on the main shaft 14, and drive the second slider 22 to move through the second motion drive servo motor 17, thereby driving the main shaft 14 to feed. At the same time, drive the third slider 21 to move upward through the third motion drive servo motor 19, so that the heat-resistant mold steel stirring head 24 approaches the upper part of the joint of the cylinder section 25, at a distance of 1.0mm from the outer surface of the cylinder section.

[0113] Step 11: Using the CNC system, the spindle 14 drives the heat-resistant mold steel stirring head 24 to rotate at a speed of 1500 r / min and is driven by the second slider 22 to advance 5.8 mm. Then, the third slider 21 is driven by the third motion drive servo motor 19 to move downward at a speed of 200 mm / min, driving the heat-resistant mold steel stirring head 24 to perform longitudinal stirring friction welding on the joint of the cylinder section 25.

[0114] Step 12: Control the drive roller 4, the first support roller 5, and the second support roller 6 through the CNC system to separate them from the joint of the cylinder section 25, thus obtaining the target cylinder section 25 product.

[0115] The manufacturing method of the present invention can achieve the integral forming of large storage tank sections by using an ultra-long plate as a blank. The manufactured section has only one weld. Compared with the conventional section made by welding 4 to 5 small blanks, the number of welds in the section is greatly reduced, the structural reliability is significantly improved, and the assembly and welding process is greatly shortened.

[0116] The manufacturing method of this invention replaces the traditional horizontal rolling bending process with a vertical rolling bending process, which can solve the problem of the influence of the changing gravitational torque caused by the shift 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 bending section can be accurately measured in the machine without having to place it vertically after removing it from the machine for measurement. Therefore, it can realize in-situ detection of rolling deformation and in-situ adjustment of rolling bending process parameters, solving the problem of repeated rolling and inspection required when using a horizontal rolling bending machine, which is cumbersome and time-consuming.

[0117] Those skilled in the art will understand that, besides implementing the system and its various devices, modules, and units provided by this invention in the form of purely computer-readable program code, the same functions can be achieved entirely through logical programming of the method steps, making the system and its various devices, modules, and units of this invention function in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers. Therefore, the system and its various devices, modules, and units provided by this invention can be considered as a hardware component, and the devices, modules, and units included therein for implementing various functions can also be considered as structures within the hardware component; alternatively, the devices, modules, and units for implementing various functions can be considered as both software modules implementing the method and structures within the hardware component.

[0118] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They 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, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0119] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A vertical roll milling and welding integrated manufacturing device for large storage tank sections, characterized in that, It includes a drive roller (4), a first support roller (5), a second support 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 component drives the first support roller (5) and the second support roller (6) to perform linear reciprocating motion in the first direction, the second moving component drives the active roller (4) and the third moving component to perform linear reciprocating motion in the second direction, and the third moving component 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 disposed between the drive 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 rotate. A milling cutter or a stirring head is provided on the main shaft (14); The active roller (4) includes a main section roller (4a) and a main movable side plate (4b). The main section roller (4a) includes a main section. 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) includes a first section roller (5a) and a first movable side plate (5b). The first section roller (5a) includes a first section. The first section roller (5a) matches the first movable side plate (5b) through the first section to form a circular roller state. The first cross-section includes two sections, which are perpendicular to each other and collinear. The second support roller (6) includes a second section roller (6a) and a second movable side plate (6b). The second section roller (6a) includes a second section. The second section roller (6a) matches the second movable side plate (6b) through the second section to form a circular roller state. The second section comprises two sections, which are perpendicular to each other and collinear.

2. The large storage tank section vertical roll milling and welding integrated manufacturing device as described in claim 1, characterized in that, A square groove is provided in the middle of the main section, and the length of the square groove is the same as the length of the main section.

3. The large storage tank section vertical roll milling and welding integrated manufacturing device as described in claim 1, characterized in that, The rotation of the main shaft (14) drives the milling cutter or stirring head to work; When a milling cutter is mounted on the spindle (14), the device includes a milling module; When a stirring head is provided on the spindle (14), the device includes a friction stir welding module.

4. The large storage tank section vertical roll milling and welding integrated manufacturing device as described in claim 1, characterized in that, It also includes a frame (1), which includes an upper base plate and a lower base plate, and at least a first moving component, a second moving component and a third moving component are respectively provided on the upper base plate and the lower base plate; The upper end and / or lower end of the first support roller (5) are connected to the first moving component; The upper and / or lower ends of the second support roller (6) are connected to the first moving component; The upper and / or lower ends of the active roller (4) are connected to the second moving component; The upper and / or lower ends of the third moving component are connected to the second moving component.

5. The large storage tank section vertical roll milling and welding integrated manufacturing device as described in claim 4, 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, which allows the cylinder section to pass through.

6. The large storage tank section vertical roll milling and welding integrated manufacturing device as described in claim 1, characterized in that, The first moving component includes a first lead screw (11), a first slider (12) and a first moving drive servo motor (9). The first slider (12) is connected to the first lead screw (11). The first moving drive servo motor (9) drives the first lead screw (11) to rotate, thereby causing the first slider (12) to move in a straight line. The second moving component includes a second lead screw (16), a second slider (22), and a second moving drive servo motor (17). 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 causing the second slider (22) to move in a straight line. The third moving component includes a third lead screw (15), a third slider (21), and a third moving drive servo motor (19). 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 causing the third slider (21) to move in a straight line. The first lead screw (11) and the second lead screw (16) are arranged perpendicularly to each other, and the third lead screw (15) and the second lead screw (16) are arranged perpendicularly to each other.

7. The large storage tank section vertical roll milling and welding integrated manufacturing device as described in claim 1, characterized in that, The rotary drive assembly includes a rotary drive servo motor (7), which comprises three sets. The three sets of rotary drive servo motors (7) drive the active roller (4), the first support roller (5), and the second support roller (6) to rotate, respectively.

8. The large storage tank section vertical roll milling and welding integrated manufacturing device according to claim 1, characterized in that, It also includes a feed roller assembly (2) and a discharge roller assembly (3). The feed roller assembly (2) includes multiple feed rollers arranged in parallel to each other, and the discharge roller assembly (3) includes multiple discharge rollers arranged in an arc.

9. A method for vertically rolling and welding integrated manufacturing of large storage tank sections, characterized in that, The large storage tank section vertical roll milling and welding integrated manufacturing apparatus according to any one of claims 1 to 8 includes the following steps: Step S1 Preset stage: Based on the preset diameter after the cylinder section is rolled, set the distance between the first support roller (5) and the second support roller (6) and drive the first support roller (5) and the second support roller (6) to the set position; Step S2: Roll forming stage Step S2.1: Push one end of the flat blank in the vertical state to between the drive roller (4) and the first support roller (5) and the second support roller (6), so that the processing surface of the flat blank contacts the surface of the first support roller (5) and the second support roller (6); Step S2.2: Control the active roller (4) to move towards the middle of the first support roller (5) and the second support roller (6) to bend the end of the flat blank; Step S2.3: Drive the first support roller (5) and the second support roller (6) to rotate, and gradually roll the flat blank into a cylindrical section (25) of a preset diameter. Step S3 Transition Phase: Step S3.1: Separate the drive 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), leaving 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 center line of the main section length direction intersects perpendicularly with the axis of the main shaft (14), 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 each other. Step S4 Milling stage: Step S4.1: Drive the main section roller (4a) to move towards the first section roller (5a) and the second section roller (6a) to clamp the conjoined section of the cylinder segment (25); Step S4.2: Install the milling cutter on the spindle (14) and drive the spindle (14) to move to the process margin near the joint of the cylinder section (25); Step S4.3: Drive the spindle (14) to rotate and move the spindle (14) up and down to realize the milling cutter to mill the process residue with the set cutting depth until the process residue 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 joint section of the cylinder segment, manually close the joint section of the cylinder segment, and control the main section roller (4a), the first section roller (5a), and the second section roller (6a) to feed back to the joint section of the cylinder segment to achieve the re-clamping of the joint section of the cylinder segment (25); Step S5.2: Install the stirring head on the main shaft (14) and drive the main shaft (14) to move until the stirring head is close to the upper part of the confluence of the cylinder section and close to the outer surface of the cylinder section (25); Step S5.3: Control the main shaft (14) to rotate and drive the main shaft (14) to move forward a set distance. By driving the main shaft (14) to move downward, the stirring head performs longitudinal stirring friction welding on the joint of the cylinder section (25).

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