A method for hardfacing wear-resistant jaw plate of double-metal jaw crusher based on field data analysis

Abstract

The present application relates to jaw crusher jaw plate processing technical field, especially in kind based on data analysis of double metal jaw crusher wear-resistant jaw plate surfacing method, including the following steps: S10: real-time acquisition of field jaw plate running data, including wear depth distribution delta, working temperature T and impact frequency f;S20: according to the field jaw plate running data to build dynamic analysis model, thereby calculating comprehensive wear parameter Ke;S30: the comprehensive wear parameter Ke and set threshold Kt are compared;When Ke>Kt, three-dimensional surfacing thickness atlas is generated, and the wire composition is dynamically adjusted;S40: the layered surfacing work is executed by using automatic surfacing machine.The present application effectively analyzes the field data in real time, adjusts the surfacing method of the jaw plate in time, and improves the quality of the jaw plate.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of jaw plate processing of jaw crushers, and particularly relates to a surfacing method for wear-resistant jaw plates of double-metal jaw crushers based on field data analysis. BACKGROUND

[0002] As core crushing equipment in the fields of mining, building materials, metallurgy, etc., the jaw plate of a double-metal jaw crusher is a key component directly involved in material crushing. In long-term operation, the jaw plate needs to withstand high-frequency impact load and material friction, and the surface is prone to failure due to problems such as wear and tear and cracks, resulting in frequent equipment downtime for maintenance, which seriously affects production efficiency and increases operating costs. To extend the service life of the jaw plate, surfacing technology forms a composite structure by depositing high-hardness wear-resistant materials on the surface of the jaw plate substrate, which has become a mainstream means to improve the wear resistance of the jaw plate.

[0003] However, the process parameters of the traditional surfacing method, such as surfacing thickness and welding wire composition, are mostly based on experience and are difficult to dynamically adapt to the actual operating conditions of the jaw plate, resulting in insufficient quality stability of the surfacing layer. The surfacing layer in the high-wear area is too thin and fails prematurely, or the surfacing layer in the low-wear area is too thick, causing material waste and thermal stress cracking, which restricts the further improvement of the performance of the jaw plate. The surfacing process lacks real-time monitoring mechanisms, and cannot timely detect temperature gradient abnormalities or crack initiation of the surfacing layer, resulting in defects that are not repaired in time, and ultimately causing the surfacing layer to peel off.

[0004] Therefore, there is a need for a surfacing method for wear-resistant jaw plates of double-metal jaw crushers based on field data analysis to effectively improve the quality of the jaw plate. SUMMARY

[0005] In view of at least one of the above technical problems, the present application provides a surfacing method for wear-resistant jaw plates of double-metal jaw crushers based on field data analysis, which adopts layered surfacing synchronous real-time monitoring and graded repair closed-loop control to solve problems such as temperature gradient out of control, early detection of cracks, and incomplete repair, and to achieve the improvement of the quality of the surfacing layer, the reduction of defect rate, and the reliability of the repair effect.

[0006] The present application provides a surfacing method for wear-resistant jaw plates of double-metal jaw crushers based on field data analysis, comprising the following steps:

[0007] S10: Real-time acquisition of field jaw plate operating data, including wear depth distribution δ, working temperature T and impact frequency f;

[0008] S20: Constructing a dynamic analysis model according to the field jaw plate operating data to calculate a comprehensive wear parameter Ke;

[0009] S30: compare the comprehensive wear parameter Ke and the set threshold Kt; when Ke>Kt, generate a three-dimensional surfacing thickness map, and dynamically adjust the wire composition;

[0010] S40: perform layered surfacing work by using an automatic surfacing machine.

[0011] In some embodiments of the present application, in step S20, a dynamic analysis model is constructed, and the comprehensive wear parameter Ke is calculated as:

[0012] Ke=δ m / δ a +λ·ln(f / T);

[0013] Wherein, δ m is the maximum wear depth; δ a is the average wear depth; λ is the working condition influence coefficient, which is a constant artificially set.

[0014] In some embodiments of the present application, in step S30, the three-dimensional surfacing thickness map generation rule is:

[0015] The surfacing base thickness is positively correlated with the maximum wear depth δ m .

[0016] Identify the wear peak area of the jaw plate, and increase the thickness;

[0017] Wherein, the wear peak area thickness increase is a multiple of the artificially set reference thickness, and the increase decreases with the increase of the distance from the peak.

[0018] In some embodiments of the present application, in step S30, dynamically adjusting the wire composition includes:

[0019] Establish Pw=P0+μ·(Ke-Kt);

[0020] Wherein, Pw is the percentage of tungsten carbide in the wire; P0 is the reference tungsten carbide proportion artificially set; μ is the proportional adjustment coefficient.

[0021] In some embodiments of the present application, in step S30, the determination method of the set threshold Kt includes:

[0022] The initial set threshold Kt is artificially set based on the design life of the jaw plate;

[0023] After completing the set number of surfacing cycles, dynamically update the set threshold according to the historical actual life data.

[0024] In some embodiments of the present application, in step S40, the layered surfacing includes:

[0025] The bottom layer uses a welding rod transition to combine with the base plate of the jaw plate.

[0026] The wear-resistant layer is formed by using a welding wire to perform layered surfacing in multiple layers;

[0027] The temperature between the layers of the wear-resistant layer is controlled to be less than a set value.

[0028] In some embodiments of the present application, in step S40, real-time monitoring is performed during the layered surfacing process, including:

[0029] The temperature field distribution of the current surfacing layer is detected in real time by using an infrared thermal imager, and when the temperature gradient exceeds a set temperature, the welding speed is reduced;

[0030] The frequency band signal of the current surfacing layer is monitored by using an acoustic emission sensor, and when a set crack characteristic frequency is identified, the current surfacing layer operation is interrupted, the three-dimensional coordinates of the crack in the current surfacing layer are recorded, and a repair program is triggered.

[0031] In some embodiments of the present application, in step S40, the repair program includes:

[0032] According to the crack characteristic frequency detected by the acoustic emission sensor, in combination with the three-dimensional coordinates of the crack, the crack is classified into a micro-crack and a through crack;

[0033] A pretreatment operation is performed on the crack: if it is a micro-crack, an angle grinder is used to clean the surface of the crack area of an oxide layer and impurities; if it is a through crack, in addition to cleaning the surface, a crack stopping hole needs to be drilled at both ends of the crack; and the repair area is locally preheated;

[0034] A layered repair welding operation is then performed on the crack: if it is a micro-crack, the same welding wire as the current surfacing layer is used to perform single-layer repair welding at a small current and low speed, and the repair welding thickness does not exceed the thickness of the original surfacing layer; if it is a through crack, a welding rod is used for transition at the bottom layer to ensure the bonding strength with the original surfacing layer and the base plate, and then layered repair welding is performed by using a welding wire;

[0035] After the repair welding is completed, the repair area is cooled to room temperature; the frequency band signal of the repair area is detected again by using the acoustic emission sensor, and if the crack characteristic frequency is not detected and the temperature gradient displayed by the infrared thermal imager is less than a set temperature, it is determined that the repair is qualified, and normal surfacing operation is resumed; if there is still an abnormality, the above steps are repeated until the repair is qualified.

[0036] In some embodiments of the present application, the welding wire is a high-chromium alloy welding wire containing tungsten carbide particles and titanium-aluminum-silicon composite hard phases.

[0037] In some embodiments of the present application, the base plate material of the jaw plate is Q235B or Q345B low-alloy steel.

[0038] The beneficial effects of the present application are: the present application collects jaw plate operation data in real time and constructs a dynamic analysis model to calculate the comprehensive wear parameter Ke, so as to achieve the goal of dynamically matching the surfacing parameters and the actual working conditions, effectively solve the problem of mismatching between the surfacing layer and the wear demand caused by the fixed parameters in the traditional method, and improve the matching accuracy of the surfacing layer thickness and the welding wire composition; by generating a three-dimensional surfacing thickness atlas and dynamically adjusting the proportion of tungsten carbide in the welding wire, the effect of accurately covering the high wear area with the surfacing layer thickness and dynamically optimizing the welding wire composition according to the wear degree is achieved; by real-time monitoring of the surfacing process and executing the standardized repair program, the surfacing layer crack rate is effectively reduced, and the bonding strength of the surfacing layer and the substrate and the quality stability are improved. BRIEF DESCRIPTION OF DRAWINGS

[0039] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0040] Figure 1 A step schematic diagram of the double-metal jaw crusher wear-resistant jaw plate surfacing method based on field data analysis in the embodiments of the present application;

[0041] Figure 2 A structure schematic diagram of the double-metal jaw crusher wear-resistant jaw plate based on field data analysis in the embodiments of the present application;

[0042] Figure 3 A structure schematic diagram of the double-metal jaw crusher wear-resistant jaw plate based on field data analysis in the embodiments of the present application; Figure 2 A structure schematic diagram of the section at A in the above figure. DETAILED DESCRIPTION

[0043] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all embodiments.

[0044] It should be noted that when an element is referred to as being "fixed" to another element, it can be directly on the other element or there can be an intervening element. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements can be present. The terms "vertical", "horizontal", "left", "right", and the like as used herein are used for illustration only and are not intended to be limiting.

[0045] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description herein is for describing particular embodiments only and is not intended to be limiting of the application. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0046] As Figures 1 to 3 The bimetallic jaw crusher wear-resistant jaw plate overlaying method based on field data analysis is shown in the following steps:

[0047] S10: Real-time acquisition of field jaw plate running data, including wear depth distribution δ, working temperature T and impact frequency f;

[0048] S20: According to the field jaw plate running data, a dynamic analysis model is constructed, and the comprehensive wear parameter Ke is calculated;

[0049] S30: Compare the comprehensive wear parameter Ke and the set threshold Kt; when Ke>Kt, generate a three-dimensional overlaying thickness atlas, and dynamically adjust the welding wire composition;

[0050] S40: Adopt an automatic overlaying machine to perform layered overlaying work.

[0051] The working principle of the application is as follows:

[0052] The traditional jaw plate overlaying repair method has significant limitations; its process parameters such as overlaying thickness distribution and welding wire alloy composition mainly rely on the experience setting of engineers or fixed standards, and lack real-time response ability to the actual running conditions of the jaw plate, such as uneven wear distribution, impact strength change and working temperature fluctuation. This leads to the possibility of insufficient overlaying in the high wear area and premature failure, and the low wear area is overlaid too thick, causing material waste and possibly cracking due to thermal stress concentration, and unable to dynamically adjust the proportion of wear-resistant hard phase such as tungsten carbide according to the wear severity and working condition severity, either insufficient wear resistance or too much toughness sacrifice.

[0053] In the present application, the real-time wear amount of each area of the jaw plate surface is obtained by non-contact measurement (such as laser scanner, 3D profiler), forming a wear depth distribution δ; the surface temperature of the jaw plate during work is monitored by an infrared temperature measuring probe to obtain the working temperature T, and the impact event frequency borne by the jaw plate is collected by an acceleration sensor or a vibration analyzer to obtain the impact frequency f, which breaks through the limitation of the traditional method relying on experience to speculate the working condition, and provides real and dynamic on-site basis for subsequent analysis; the discrete on-site jaw plate running data (wear depth distribution δ, working temperature T, impact frequency f) collected in step S10 are input into a dynamic analysis model for correlation and integration, and an integrated wear parameter Ke is output to quantitatively represent the overall damage degree of the jaw plate and the severity of the working condition, solving the problem that the traditional method cannot scientifically evaluate the wear state; based on the comparison with the set threshold Kt, the three-dimensional overlay thickness map is generated and the welding wire composition is dynamically adjusted, ensuring the synchronous matching of the wear resistance and the working condition demand, and finally the automatic overlaying machine is used to execute the operation, converting the above dynamically adjusted parameters into actual operation, and ensuring the consistency and accuracy of the overlaying process.

[0054] Compared with the traditional method, the present application realizes the high adaptation of the overlay thickness, the welding wire composition, the actual wear degree of the jaw plate and the working condition through the closed loop process of data collection, model analysis, parameter adjustment and precise execution, effectively avoids the problems of failure due to too thin or cracking due to too thick, and significantly improves the quality stability of the overlay; at the same time, the dynamic adjustment mechanism based on real-time data can also prolong the wear life of the jaw plate, reduce the frequency of equipment downtime maintenance, and reduce the whole life cycle operation cost, thereby providing key technical support for the efficient and stable operation of the double-metal jaw crusher.

[0055] In some embodiments of the present application, in step S20, a dynamic analysis model is constructed to calculate the integrated wear parameter Ke as follows:

[0056] Ke = δ m / δ a + λ · ln(f / T);

[0057] Wherein, δ m is the maximum wear depth; δ a is the average wear depth; λ is the working condition influence coefficient, which is a constant artificially set.

[0058] Step S20 calculates the integrated wear parameter Ke by constructing a dynamic analysis model, the purpose of which is to integrate the discrete on-site data into a single index that can be quantified and compared, thereby providing a scientific basis for subsequent overlaying decision; the maximum wear depth δ m in the formula and the average wear depth δ aThe ratio of the two parts intuitively reflects the unevenness of the jaw plate surface wear distribution, the larger the ratio, the more severe the local wear, which needs to be highlighted; and λ·ln(f / T) quantifies the dynamic severity of the working condition through the logarithmic relationship of the impact frequency f and the working temperature T, the higher the f and the lower the T, the larger the ln(f / T) value, the more severe the working condition. By combining these two parts, the comprehensive wear parameter Ke can not only capture where the wear is most severe, but also evaluate how much the current working condition affects the wear, so as to comprehensively depict the damage state of the jaw plate and the working condition characteristics, ensure that the subsequent generated three-dimensional surfacing thickness map (for strengthening high wear areas) and welding wire composition adjustment (increase the proportion of tungsten carbide according to the severity of the working condition) are more in line with actual needs, and significantly improve the quality stability of the surfacing layer.

[0059] In some embodiments of the present application, in step S30, the three-dimensional surfacing thickness map generation rule is:

[0060] The surfacing base thickness and the maximum wear depth δ m positively correlated;

[0061] Identify the peak wear area of the jaw plate and increase the thickness;

[0062] Wherein the wear peak area thickness increment is a multiple of the artificially set reference thickness, and the increment decreases with the increase of the distance from the peak.

[0063] Such a design ensures that the overall thickness of the surfacing layer is directly related to the most severe local maximum wear depth δ m of the jaw plate, and the larger the maximum wear depth δ m , the thicker the base thickness, fundamentally avoiding the problem of insufficient high wear area or excessive low wear area caused by global uniform thickness in traditional methods; the mechanism of identifying the wear peak area and increasing the thickness, and the increment decreasing with the increase of the distance from the peak, further strengthens the protection of the most critical area, and the peak area such as the tooth tip with the most severe wear can obtain additional thickness addition, ensuring that its wear resistance is highly matched with the actual demand; with the increase of the distance from the peak area, the increment gradually decreases, which not only avoids excessive surfacing of non-critical areas, reduces material waste and thermal stress risk, but also realizes smooth transition of the surfacing layer thickness through gradient change, improving the mechanical stability of the overall structure.

[0064] On the basis of the above embodiments, in step S30, dynamically adjusting the welding wire composition includes:

[0065] Establish Pw=P0+μ·(Ke-Kt);

[0066] Wherein Pw is the percentage of tungsten carbide in the welding wire; P0 is the reference tungsten carbide proportion artificially set; μ is the proportion adjustment coefficient.

[0067] When the working condition is poor, such as high impact frequency and severe local wear, the jaw plate of the bimetallic jaw crusher needs a higher proportion of tungsten carbide to enhance wear resistance; when the working condition is relatively mild, too high a content of tungsten carbide may reduce the toughness of the surfacing layer and increase the risk of cracking. Therefore, in the embodiment, the difference between the comprehensive wear parameter Ke and the set threshold Kt directly represents the deviation of the current wear degree from the critical state, and the percentage Pw of the mass of tungsten carbide increases with the increase of the difference, and the wear resistance of the surfacing layer is enhanced by increasing the proportion of tungsten carbide; when the comprehensive wear parameter Ke is close to or less than the set threshold Kt, the percentage Pw of the mass of tungsten carbide is correspondingly reduced, so as to avoid the toughness reduction and material waste caused by too much tungsten carbide.

[0068] On the basis of the above embodiment, in step S30, the determination method of the set threshold Kt includes:

[0069] The initial set threshold Kt is set based on the design life of the jaw plate;

[0070] After completing the set number of surfacing cycles, the set threshold is dynamically updated according to historical actual life data.

[0071] The wear rate and life of the jaw plate of the bimetallic jaw crusher in actual operation are affected by many factors such as material hardness, operation frequency, and environmental temperature, and the actual wear law in different application scenarios may deviate from the theoretical assumption in design. The initial set threshold Kt is set based on the design life, which ensures the basic reliability of the surfacing strategy and avoids arbitrary setting without basis; after completing the set number of surfacing cycles, the set threshold Kt is dynamically updated according to historical actual life data, which introduces an updating mechanism. If the actual life is higher than the design life, it means that the jaw plate is more durable under the current working condition, and the set threshold Kt can be appropriately increased to delay the surfacing triggering and reduce unnecessary operations; if the actual life is lower than the design life, it means that the working condition is more severe or the initial setting is conservative, and the set threshold Kt is reduced to trigger the surfacing in advance to enhance protection. Such design improves the robustness and practicality of the surfacing scheme, and makes the quality stability of the surfacing layer and the life of the jaw plate no longer dependent on the initial preset, but continuously optimized with the accumulation of equipment operation data, providing more flexible and scientific technical support for the long-term reliable operation of the bimetallic jaw crusher.

[0072] In some embodiments of the present application, in step S40, the layered surfacing includes:

[0073] The bottom layer uses a structural electrode or a low-hydrogen electrode to transition and combine with the base plate of the jaw plate;

[0074] The wear-resistant layer uses high-chromium or tungsten carbide welding wire to layer surfacing multiple layers, and preferably each layer of layered surfacing has a thickness of 1-3 mm, and the temperature between each layer is controlled below 300℃;

[0075] The interlayer temperature of the wear-resistant layer is controlled to be less than a set value, and the surfacing parameters are set as follows: current 220-280 A, voltage 22-28 V, protective gas CO2 or argon (flow rate 20 L / min), and welding speed 35 cm / min.

[0076] The structural electrode has good metallurgical compatibility with the base plate composition, and can reduce stress concentration caused by the difference in the coefficient of thermal expansion through composition transition; the low-hydrogen electrode can significantly reduce the generation of interface pores and micro-cracks due to the extremely low hydrogen content, and the combination strength of the surfacing layer and the base plate is greatly improved under the dual action, thereby fundamentally reducing the risk of surfacing layer falling off.

[0077] The wear-resistant layer is layered surfacing (1-3 mm per layer) using high-chromium or tungsten carbide welding wire, and the interlayer temperature is controlled to be less than or equal to 300°C, which is a better regulation of the internal organization and stress. The traditional single-layer thick welding is prone to form coarse martensite or residual tensile stress due to the fast cooling speed of the molten pool and the large internal temperature gradient, which leads to cracks; and the present process reduces the single heat input by layering, makes the molten pool cool more evenly, refines the grains, and at the same time, the interlayer temperature is limited to be less than or equal to 300°C to avoid heat accumulation caused by continuous welding, which further inhibits grain coarsening and phase transformation stress, so that the internal organization of the wear-resistant layer is more compact and the residual stress is reduced, and the crack resistance is significantly improved.

[0078] The standardized surfacing parameters guarantee the process stability, and the combination of the two makes the composition uniformity of the surfacing layer improved and the porosity reduced, thereby guaranteeing the quality consistency of the wear-resistant layer from the source.

[0079] On the basis of the above embodiments, in step S40, real-time monitoring is performed during the layered surfacing process, including:

[0080] An infrared thermal imager is used to detect the temperature field distribution of the current surfacing layer in real time, and when the temperature gradient exceeds the set temperature, the welding speed is reduced;

[0081] An acoustic emission sensor is used to listen to the frequency band signal of the current surfacing layer, and when the set crack characteristic frequency is identified, the current surfacing layer operation is interrupted, the three-dimensional coordinates of the crack in the current surfacing layer are recorded, and a repair program is triggered.

[0082] During the surfacing process, if the local temperature gradient exceeds the set threshold, it means that this area is accumulating residual stress due to uneven cooling, which may cause cracks. In the traditional process, this temperature anomaly can only be determined by manual touch or experience, which has a large error and strong lagging effect, while the infrared thermal imager can generate a temperature field distribution map in real time, and when the gradient exceeds the standard, the system automatically reduces the welding speed to prolong the cooling time of the molten pool, so that the temperature distribution tends to be uniform, thereby fundamentally inhibiting stress concentration and reducing the initial inducement of micro-cracks.

[0083] When the overlay layer generates micro-cracks under stress, it will release elastic wave signals of specific frequency. The traditional process cannot capture such signals due to the lack of real-time acquisition and analysis equipment, and the cracks are not discovered until they expand into visible defects. In the embodiment, the signals are acquired in real time by the acoustic emission sensor, and the preset crack characteristic frequency database is combined to identify and trigger the interrupt instruction when the crack length is very short, so as to immediately stop the current layer welding, record the three-dimensional coordinates of the crack, and start the repair program, thereby avoiding the further expansion of the defect with subsequent welding and greatly reducing the repair cost.

[0084] In some embodiments of the application, in step S40, the repair program comprises:

[0085] According to the crack characteristic frequency detected by the acoustic emission sensor, combined with the three-dimensional coordinates of the crack, the crack is divided into micro-cracks and through cracks;

[0086] The crack is subjected to a pretreatment operation: if it is a micro-crack, the surface of the crack area is cleaned of the oxidation layer and impurities by an angle grinder; if it is a through crack, in addition to cleaning the surface, a crack stopping hole is also drilled at both ends of the crack; and the repair area is locally preheated;

[0087] The crack is subjected to a layered repair welding operation: if it is a micro-crack, the same welding wire as the current overlay layer is used for single-layer repair welding at a small current and low speed, and the repair welding thickness is not more than the original overlay layer thickness; if it is a through crack, the bottom layer is transitioned by a welding rod to ensure the bonding strength with the original overlay layer and the substrate, and then layered repair welding is performed by a welding wire;

[0088] After the repair welding is completed, the repair area is cooled to room temperature; the frequency band signal of the repair area is detected again by the acoustic emission sensor, if the crack characteristic frequency is not detected, and the temperature gradient displayed by the infrared thermal imager is less than the set temperature, it is determined that the repair is qualified, and the normal overlay operation is resumed; if there is still an abnormality, the above steps are repeated until the repair is up to standard.

[0089] The traditional process often mixes micro-cracks with short length and not penetrating the overlay layer with through cracks with long length and penetrating the overlay layer or even reaching the substrate due to the lack of crack characteristic analysis, resulting in over-treatment of micro-cracks or insufficient treatment of through cracks. In the embodiment, the crack characteristic frequency of the acoustic emission sensor, such as the high-frequency short signal corresponding to the micro-crack and the low-frequency long signal corresponding to the through crack, is combined with the three-dimensional coordinates for classification, which provides a basis for subsequent pretreatment and repair welding. The micro-crack only needs surface cleaning, and the through crack needs to be drilled with a crack stopping hole to prevent crack expansion, thereby avoiding material waste caused by traditional uniform polishing or secondary expansion caused by missing crack stopping.

[0090] And for micro-cracks, small current (such as 200 to 240A) and low speed (welding speed 25cm / min) single-layer repair welding is adopted to reduce thermal stress and avoid overburning, and the repair layer and the original layer are more closely combined; through the bottom layer electrode transition, the composition of the base plate / original surfacing layer is matched, the interface bonding is enhanced, and the wear-resistant layer is layered for repair welding to avoid stress accumulation of thick layer repair welding. At the same time, the surface oxide layer cleaning and local preheating in the pretreatment further reduce the interface porosity and cold cracks.

[0091] Then, the repaired area is rechecked by the acoustic emission sensor to detect whether there is still a crack characteristic frequency, and the temperature is measured by the infrared thermal imager to ensure that the defect is completely eliminated; if there is still an abnormality, the repair is repeated until the standard is met, so that the repaired surfacing layer has stable performance in subsequent surfacing or actual operation.

[0092] In some embodiments of the present application, the welding wire is a high-chromium alloy welding wire containing tungsten carbide particles and titanium-aluminum-silicon composite hard phase.

[0093] High-chromium alloy (Cr content 15% to 20%) itself has excellent anti-abrasive wear ability, and the tungsten carbide particles as hard phase have a Vickers hardness of 2000-2500HV, which is much higher than the 800-1000HV of high-chromium alloy, and can form an anti-abrasive layer on the surface of the surfacing layer to directly resist the impact and friction of the ore; the titanium-aluminum-silicon composite hard phase (such as TiC, Al2O3, SiC) further improves the high-temperature stability and fatigue resistance of the surfacing layer through grain refinement and dispersion strengthening.

[0094] In some embodiments of the present application, the base plate material of the jaw plate is Q235B or Q345B low-alloy steel. These two materials have low cold crack sensitivity in the heat-affected zone during surfacing, providing a good metallurgical basis for the bottom electrode transition. At the same time, the yield strength of Q345B is higher than that of Q235B, which can provide stronger structural support to the jaw plate when it is impacted by the ore, avoiding the surfacing layer from falling off due to deformation of the base plate. More importantly, the thermal expansion coefficient of low-alloy steel and high-chromium welding wire is highly matched, which is much lower than the thermal expansion difference between traditional high-manganese steel and welding wire, reducing the degree of interface stress concentration and improving the bonding strength, effectively reducing the risk of surfacing layer falling off.

[0095] Those skilled in the art should understand that the present application is not limited by the above embodiments, and the above embodiments and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis, characterized in that, Includes the following steps: S10: Real-time acquisition of jaw plate operation data, including wear depth distribution δ, operating temperature T, and impact frequency f; S20: Construct a dynamic analysis model based on the on-site jaw plate operation data to calculate the comprehensive wear parameter Ke; S30: Compare the comprehensive wear parameter Ke with the set threshold Kt; when Ke > Kt, generate a three-dimensional weld overlay thickness map and dynamically adjust the welding wire composition; S40: Uses an automatic welding machine to perform layered welding work.

2. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 1, characterized in that, In step S20, a dynamic analysis model is constructed to calculate the comprehensive wear parameter Ke: WHδ m / δ a +λ·ln(f / T) Where, δ m The maximum wear depth; δ a λ represents the average wear depth; λ is the operating condition influence coefficient, which is a constant set by the user.

3. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 1, characterized in that, In step S30, the rule for generating the three-dimensional weld overlay thickness map is as follows: The thickness of the weld overlay base and the maximum wear depth δ m Positive correlation; Identify the peak wear area of ​​the jaw plate and increase its thickness accordingly; The thickness increase of the wear peak region is a multiple of a manually set reference thickness, and the increase decreases as the distance from the peak increases.

4. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 1, characterized in that, In step S30, dynamically adjusting the welding wire composition includes: Establish Pw = P0 + μ·(Ke - Kt); Where Pw is the percentage of tungsten carbide mass in the welding wire; P0 is the manually set baseline tungsten carbide ratio; and μ is the ratio adjustment coefficient.

5. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 1, characterized in that, In step S30, the method for determining the threshold Kt includes: The initial threshold Kt is set manually based on the jaw plate's design life; After completing a set number of welding cycles, the set threshold is dynamically updated based on historical actual lifespan data.

6. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 1, characterized in that, In step S40, the layered welding includes: The bottom layer is transitioned using welding rods and bonded to the substrate of the jaw plate; The wear-resistant layer is constructed by layering multiple layers of welding wire. Specifically, the interlayer temperature of the wear-resistant layer is controlled to be less than a set value.

7. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 6, characterized in that, In step S40, real-time monitoring is performed simultaneously during the layered welding process, including: Infrared thermal imagers are used to detect the temperature field distribution of the current weld overlay in real time. When the temperature gradient exceeds the set temperature, the welding speed is reduced. The system uses an acoustic emission sensor to monitor the frequency band signal of the current weld overlay. When the set crack characteristic frequency is detected, the current weld overlay operation is interrupted, the three-dimensional coordinates of the crack in the current weld overlay are recorded, and the repair procedure is triggered.

8. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to claim 7, characterized in that, In step S40, the repair procedure includes: Based on the characteristic frequency of the crack detected by the acoustic emission sensor, and combined with the three-dimensional coordinates of the crack, the crack is divided into microcracks and through cracks. Pre-treatment of cracks: For microcracks, use an angle grinder to clean the oxide layer and impurities on the surface of the crack area; for through cracks, in addition to cleaning the surface, it is necessary to drill anti-crack holes at both ends of the crack; and preheat the repair area locally. Next, perform layered welding repair on the cracks: If it is a micro-crack, use the same welding wire as the current weld overlay, and perform single-layer welding with low current and low speed. The thickness of the repair welding should not exceed the thickness of the original weld overlay. If it is a through crack, use welding rods to transition the bottom layer to ensure the bonding strength with the original weld overlay and the substrate, and then use welding wire to repair the cracks in layers. After the repair welding is completed, the repaired area is cooled to room temperature; the frequency signal of the repaired area is detected again by the acoustic emission sensor. If no crack characteristic frequency is detected and the infrared thermal imager shows that the temperature gradient is less than the set temperature, the repair is deemed qualified and normal welding operation is resumed; if there is still an abnormality, the above steps are repeated until the repair meets the standard.

9. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to any one of claims 1 to 8, characterized in that, The welding wire is a high-chromium alloy welding wire containing tungsten carbide particles and a titanium-aluminum-silicon composite hard phase.

10. The method for surfacing wear-resistant jaw plates of a bimetallic jaw crusher based on field data analysis according to any one of claims 1 to 8, characterized in that, The base material of the jaw plate is Q235B or Q345B low alloy steel.

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