Flux-cored wire filling process and filling device

Abstract

The invention relates to a flux-cored wire filling technology and a filling device, relates to the technical field of flux-cored wire preparation, and solves the problems that in the existing flux-cored wire machining process, flux core components are prone to layering, machined welding wires are inconsistent in component and large in fluctuation, the flux core filling content is uneven, and the porosity of finished welding wires is increased. Comprising the following steps: preparing and storing a flux core, carrying out high-frequency micro-vibration on the stored flux core material, blanking and weighing, and controlling the thickness, width and conveying speed of the flux core material in the conveying process of the flux core material; the size and the running speed of the U-shaped steel belt, the discharging speed before weighing and the conveying speed, the thickness and the width of a flux core material before powder is discharged to the U-shaped steel belt are collected in real time, data collected in real time are compared with set filling process parameters to analyze whether the data are within a set range or not, and timing calibration is conducted; the device has the effects of solving the problem of powder layering, improving the filling rate, reducing the porosity of a finished product and improving the processing efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of flux-cored wire preparation, in particular to a flux-cored wire filling process and filling device. BACKGROUND

[0002] The existing patent publication number "CN111843296A" discloses a flux-cored wire forming machine and a flux-cored wire forming process, mainly relating to the field of flux-cored wire forming machines. It includes a steel strip U-shaped groove device, a joint device, and also includes a first powder adding machine and a second powder adding machine. The beneficial effects of the present application are that it solves the problem of uneven distribution of graphite powder in the flux-cored wire during the powder filling process of slag-free self-protection flux-cored wire, because the density of graphite powder is less than that of metal powder, which leads to uneven mixing of the powder and uneven distribution of graphite powder in the wire. By filling graphite powder and other powders into the wire separately, the filling rate dispersion coefficient of the wire is reduced and the filling of graphite is more uniform, effectively improving the quality of the wire.

[0003] The above description has the following problems. When processing flux-cored wire, the powder in the first powder adding machine is usually directly discharged into the U-shaped steel strip. The density of each component of the prepared powder (such as metal powder and mineral powder) is greatly different, and the components are prone to stratification, resulting in inconsistent composition of the processed wire with large fluctuations. Moreover, when filling the powder, the discharge speed of the powder and the conveying speed of the U-shaped steel material are not within the set range, and when there is a deviation, it cannot be adjusted in time, resulting in uneven content of the powder in the U-shaped steel material, insufficient filling rate, affecting the deposition efficiency of the wire, and air mixing into the flux-cored wire during the filling process, leading to an increase in the porosity of the wire product and difficulty in matching the high-speed drawing requirement. SUMMARY

[0004] The purpose of the present application is to provide a flux-cored wire filling process and filling device, which solves the problems of stratification of powder components, inconsistent composition of processed wire, large fluctuations, uneven filling content of powder, and high porosity of wire product in the existing flux-cored wire processing process.

[0005] To achieve the above-mentioned purpose, the technical solution adopted by the present application is: The present application provides a flux-cored wire filling process, comprising the following steps: S1, mixing and stirring the various raw material components of the prepared powder material according to the proportion and storing, wherein the storage amount is controlled according to the set working requirement, and the excess powder material beyond the set working requirement is stored for heat preservation; S2, selecting the size of the flat steel strip and conveying and rolling the flat steel strip with the selected size to form a U-shaped steel strip; S3, high frequency micro-vibration is carried out on the stored drug core material, and the drug core material is discharged and weighed, and the thickness, width and conveying speed of the drug core material in the conveying process are controlled to uniformly powder the drug core material into the U-shaped steel belt; S4, before filling, the welding wire filling process parameters are set, during the filling process, the size and running speed of the U-shaped steel belt, the discharging speed before weighing, and the conveying speed, thickness and width of the drug core material before powdering into the U-shaped steel belt are collected in real time, the collected data are compared with the set filling process parameters to analyze whether they are within the set range, and the size and running speed of the U-shaped steel belt, the discharging speed before weighing, and the conveying speed, thickness and width of the drug core material before powdering into the U-shaped steel belt are calibrated in real time to realize real-time adjustment of the flow of the drug core material powdering into the U-shaped steel belt in S2; S5, the U-shaped steel belt filled with the drug core is pressed and rolled, and is drawn into a shape.

[0006] Further, in the S1, the upper limit and the lower limit of the feeding are set according to the actual demand of the drug core material, and an alarm is given when the drug core material is not within the set value.

[0007] Further, in the S4, an alarm is given when the powder flow changes beyond the set range.

[0008] Further, in the S4, the filling data collected in real time during the discharging process can be transmitted and saved through the MES system.

[0009] The application further provides a drug core welding wire filling device, which comprises: A powder bin is arranged on the powder bin for storing the drug core material, and a vibrating body is arranged on the powder bin for high frequency micro-vibration of the drug core material in the powder bin. A weighing belt conveyor is arranged below the discharge port of the powder bin. A filler conveying belt is arranged at the discharge port of the weighing belt conveyor, and a U-shaped steel belt to be filled is arranged below the discharge port of the filler conveying belt, and the conveying direction of the U-shaped steel belt is perpendicular to the conveying direction of the filler conveying belt. A lower gate plate assembly is arranged in a lifting manner, and the lower gate plate assembly is used for controlling the thickness of the drug powder material on the filler conveying belt.

[0010] Further, a standby heat preservation bin is further arranged, and the standby heat preservation bin is used for storing excess drug core material.

[0011] Further, detectors are further arranged on the powder bin respectively for detecting the feeding and discharging positions of the drug core material in the powder bin.

[0012] Further, a positioning assembly for positioning the U-shaped steel belt is further included, and the positioning assembly includes at least two positioning roller groups, and the two positioning roller groups are located at the discharge end of the filler conveying belt and are arranged at intervals along the conveying direction of the U-shaped steel belt.

[0013] Further, a guide member is arranged directly below the discharge end of the filler conveying belt, and the guide member includes a support seat and two vertical plates arranged on the upper end surface of the support seat, and the two vertical plates are arranged at intervals to form a limiting cavity for the steel belt to pass through.

[0014] Thanks to the above technical scheme, the present application has the following advantages compared with the prior art: The powder filling process and device of the present application can solve the problem of powder layering, and can adjust the speed of powder discharge from the powder bin, the speed of the filler conveying belt, the width and thickness of the powder before being filled into the U-shaped steel material, and the conveying speed of the U-shaped steel material in real time during the filling process, so that each parameter process is within the set parameter range, thereby ensuring the uniformity of the powder material filled into the U-shaped steel material, improving the filling rate, avoiding the mixing of air during the filling process since the U-shaped steel material is filled with the powder core material, reducing the porosity of the powder core welding wire product, and improving the processing efficiency of the powder core welding wire. BRIEF DESCRIPTION OF DRAWINGS

[0015] Some specific embodiments of the present application will be described in detail hereinafter with reference to the accompanying drawings in an exemplary and non-limiting manner. The same reference numerals in the drawings denote the same or similar components or parts. Those skilled in the art should understand that the drawings are not necessarily drawn to scale. In the drawings: Figure 1 is a schematic view of the overall structure of a preferred embodiment of the present application; Figure 2 is a sectional view of the overall structure of a preferred embodiment of the present application; Figure 3 is a schematic view of the structure of the lower gate plate assembly in a preferred embodiment of the present application; Figure 4 is a sectional view of the lower gate plate assembly in a preferred embodiment of the present application; Figure 2 is an enlarged view of A in

[0016] In the drawings, the reference numerals are explained as follows: 1, powder bin; 2, weighing belt machine; 3, filler conveying belt; 4, lower gate plate assembly; 41, side plate; 42, valve plate body; 43, roller; 5, U-shaped steel belt; 6, vibrating body; 7, groove; 8, detector; 9, positioning assembly; 91, positioning roller group; 10, material guide; 101, support seat; 102, vertical plate. DETAILED DESCRIPTION

[0017] The technical solutions of the present application will be described clearly and completely below with reference to the drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0018] In the description of the present application, it should be noted that the orientations or positional relationships indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0019] In addition, the technical features involved in different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0020] Reference Figure 1 And Figure 2 A flux-cored wire filling device provided by the present application comprises a powder bin 1, a weighing belt machine 2 arranged below the discharge port of the powder bin 1, a filler conveying belt 3 arranged at the discharge port of the weighing belt machine 2, a lower gate assembly 4, and a standby heat preservation bin (not shown in the figure), and the conveying direction of the rolled U-shaped steel belt 5 is perpendicular to the conveying direction of the filler conveying belt 3.

[0021] Reference Figure 1 And Figure 2 The powder bin 1 is used for storing the flux-cored material to be filled, and the standby heat preservation bin is used for storing the excess flux-cored material. The relative humidity of the storage environment in the standby heat preservation bin is controlled to be ≤10%, so that the caking of the stored flux-cored material can be avoided. When the flux-cored material in the standby heat preservation bin is used again to prepare the flux-cored wire, the flux-cored material has good flowability, and the discharging is convenient.

[0022] Reference Figure 1 And Figure 2The material powder bin 1 is provided with a vibration body 6 for high-frequency micro-vibration of the core material therein; the high-frequency micro-vibration (50-100 Hz) generated by the vibration body 6 can eliminate the gaps in the core material and meet the uniform powder feeding; secondly, the core material can be mixed again under the vibration of the high-frequency micro-vibration, and the mixing of the various components of the core material under the vibration can avoid the stratification of the core material during the powder feeding process, so as to ensure the powder feeding accuracy.

[0023] With reference to Figure 1 , Figure 2 and Figure 3 , the lower gate assembly 4 is arranged above the filler conveying belt 3, and the lower gate assembly 4 is used to control the thickness and width of the powder material on the filler conveying belt 3. The lower gate assembly 4 includes two side plates 41 arranged oppositely and in parallel, and a valve plate body 42 arranged between the two side plates 41. The spacing between the two side plates 41 can be designed according to actual needs, and the gate plate body 42 can be adjusted longitudinally between the two side plates 41. The bottom end surface of the two side plates 41 is in gap cooperation with the upper end surface of the filler conveying belt 3. When the core material on the filler conveying belt 3 passes through the lower gate assembly 4, the width and thickness required by the core material are accurately controlled under the cooperation of the two side plates 41 and the gate plate body 42. The side surfaces of the two side plates 41 are provided with rollers 43, and the filler conveying belt 3 is provided with grooves 7 matched with the rollers 43. The cooperation of the rollers 43 and the grooves 7 improves the stability of the lower gate assembly 4, and further improves the accuracy of the width and thickness control of the core material, thereby ensuring the powder feeding accuracy of the core wire.

[0024] With reference to Figure 1 , Figure 2 and Figure 3 , the material powder bin 1 is further provided with a detector 8 for detecting the upper and lower positions of the core material therein. The upper and lower position limits in the material bin 1 can be designed according to actual needs, such as the maximum range of the upper limit of feeding, which is 150 Kg, and the minimum range of the lower limit of feeding, which is 3 Kg. When the material level reaches the maximum upper limit during feeding, the upper feeding can be automatically controlled to be closed by the control assembly, and an alarm is prompted. When the value is less than the minimum limit, the lower valve of the material bin 1 is automatically controlled to be closed, and an alarm is prompted. Therefore, the upper and lower position detectors 8 can control the automatic feeding of the material bin 1.

[0025] With reference to Figure 1 , Figure 2 and Figure 4 , it further includes a positioning assembly 9 for positioning the U-shaped steel belt 5. The positioning assembly 9 includes at least two positioning roller groups 91, which are located at the discharge end of the filler conveying belt 3 and are arranged in intervals along the conveying direction of the U-shaped steel belt 5. The positioning assembly 9 can limit the position of the conveyed U-shaped steel belt 5, avoid shaking during filling, and reduce the filling accuracy.

[0026] Referring to Figure 1 , Figure 2 and Figure 4 , a material guiding member 10 is arranged directly below the discharge end of the filler conveying belt 3, and two positioning roller groups 91 are arranged on the two sides of the material guiding member 10. The material guiding member 10 comprises a support seat 101 and two vertical plates 102 arranged on the upper end surface of the support seat. The two vertical plates 102 are arranged in a spaced manner to form a limiting cavity for the U-shaped steel belt 5 to pass through. When the U-shaped steel belt 5 passes through the limiting cavity, the U-shaped steel belt 5 can also be limited in the conveying process, thereby improving the stability of the conveying and preventing shaking.

[0027] Referring to Figures 1-4 , the flux-cored wire filling process comprises the following steps: S1, mixing and stirring the various raw material components for preparing the flux-cored material according to the proportion, and storing the stirred flux-cored material in the material distribution bin 1. The storage amount is controlled according to the set work requirement. According to the actual work requirement, the upper limit and the lower limit of the material feeding are set, and an alarm is given when the flux-cored material is not within the set value. The excess flux-cored material after mixing and stirring and exceeding the set work requirement can be used for filling of the next wire. S2, selecting the size of the plane steel belt, conveying and rolling the plane steel belt with the selected size, rolling the plane steel belt into a U-shaped steel belt 5, and conveying the rolled U-shaped steel belt 5 to the discharge end of the filler conveying belt 3.

[0028] S3, high-frequency micro-vibration of the flux-cored material stored in the material powder bin 1 by the vibration body 6, opening the lower valve of the material powder bin 1 to discharge and weigh on the weighing belt conveyor 2 at the same time of vibration, conveying the flux-cored material to the filler conveying belt 3 after weighing, controlling the rotating speed of the filler conveying belt 3 and calibrating at regular time intervals, and controlling and scraping the thickness and width of the flux-cored material on the filler conveying belt 3 by the lower gate assembly 4 in the conveying process, so as to ensure the uniformity of the flux-cored content in the U-shaped steel material. S4, before filling, set the welding wire filling process parameters, and manually input the set welding wire filling process parameters into the control system range box, complete dynamic calibration; during filling, real-time acquisition of the size and running speed of the U-shaped steel belt 5, the discharging speed of the material bin 1 before weighing, and the conveying speed, thickness and width of the core material before powdering to the U-shaped steel belt, compare the real-time acquisition data with the set filling process parameters to analyze whether it is within the set range, and calibrate the size and running speed of the U-shaped steel belt, the discharging speed before weighing, and the conveying speed, thickness and width of the core material before powdering to the U-shaped steel belt 5 at regular intervals, realize real-time adjustment of the flow of the core material powdering to the U-shaped steel belt 5; when the powdering flow changes beyond the set range, alarm prompt. The filling data collected in real time during filling can be transmitted and saved through the MES system, and used as the basis for welding wire quality traceability.

[0029] S5, the U-shaped steel belt 5 filled with the core is pressed and rolled, and drawn into a shape.

[0030] Reference Figures 1-4 By using the core filling device and the filling process, the problem of powder layering can be solved, the speed of the material bin 1 discharging, the speed of the filling conveying belt 3, the width and thickness of the core material before powdering to the U-shaped steel 5, and the conveying speed of the U-shaped steel 5 can be real-time calibrated and adjusted during the filling process, so that each parameter process is within the set parameter range, thereby ensuring the uniformity of the powder material powdering to the U-shaped steel, improving the filling rate, and avoiding the mixing of air in the filling process because the U-shaped steel is filled with the core material, reducing the porosity of the core wire product, and improving the processing efficiency of the core wire. Referring to the following table: Indicator Conventional process Process of the invention Lift range Filling uniformity CV value ≥ 8% CV value ≤ 2% ↑75% Limiting filling rate 92% 99.5% ↑8.2% Welding wire porosity 0.5~0.8% ≤0.1% ↓80% Production speed 1130 r / min 1400 r / min ↑23.9% The above examples are only for illustrating the technical concept and characteristics of the present application, the purpose is to enable those skilled in the art to understand the content of the present application and implement it, and cannot limit the protection scope of the present application, any equivalent changes or modifications made according to the spirit and essence of the present application should be covered within the protection scope of the present application.

Claims

1. A flux cored welding wire filling process characterized by, It comprises the following steps: S1, the various raw material components of the prepared core material are mixed and stirred according to the proportion and stored, wherein the storage amount is controlled according to the set work requirement, and the excess core material exceeding the set work requirement is stored for heat preservation; S2, the size of the plane steel strip is selected, and the plane steel strip with the selected size is transported and rolled to roll the plane steel strip into a U-shaped strip; S3, the stored core material is subjected to high-frequency micro-vibration and is discharged and weighed, and the core material after weighing is transported, wherein the thickness, width and transportation speed of the core material are controlled in the transportation process, so that the core material is uniformly discharged into the U-shaped steel strip; S4, before filling, the welding wire filling process parameters are set; during the filling process, the size and running speed of the U-shaped steel strip, the discharging speed before weighing, and the core material conveying speed, thickness and width before discharging into the U-shaped steel strip are collected in real time, the collected data are compared with the set filling process parameters to analyze whether they are within the set range, and the size and running speed of the U-shaped steel strip, the discharging speed before weighing, and the core material conveying speed, thickness and width before discharging into the U-shaped steel strip are calibrated at regular intervals to realize real-time adjustment of the flow of the core material discharged into the U-shaped steel strip in S2; S5, the U-shaped steel strip filled with the core is subjected to pressing, rolling, sewing and drawing forming.

2. The flux cored wire filling process of claim 1, wherein, In the S1, the upper limit and lower limit of the feeding amount are set according to the actual work requirement of the core material, and an alarm is given when the core material is not within the set value.

3. The flux cored wire filling process of claim 1 wherein, In the S4, an alarm is given when the change of the discharging flow exceeds the set range.

4. The flux cored wire filling process of claim 1 wherein, In the S4, the filling data collected in real time during the discharging process can be transmitted and saved through the MES system.

5. A drug core welding wire filling device characterized by, It comprises: The powder bin (1) is used for storing the core material, and a vibrating body (6) for high-frequency micro-vibration of the core material in the powder bin (1) is arranged on the powder bin (1); The weighing belt conveyor (2) is arranged below the discharge port of the powder bin (1); The filler conveying belt (3) is arranged at the discharge port of the weighing belt conveyor (2), the U-shaped steel strip (5) to be filled is arranged below the discharge port of the filler conveying belt (3), and the conveying direction of the U-shaped steel strip (5) is perpendicular to the conveying direction of the filler conveying belt (3); The lower gate assembly (4) can be lifted and lowered, and is used to control the thickness and width of the filler powder material on the filler conveying belt (3).

6. The flux cored wire filling device of claim 5, wherein, It also comprises a standby heat preservation bin for storing excess core material.

7. The drug core wire filler device of claim 5 or 6, wherein, The powder bin (1) is also provided with a detector (8) for detecting the upper and lower positions of the core material therein.

8. The flux cored wire filling device of claim 5, wherein, It also comprises a positioning assembly (9) for positioning the steel strip, and the positioning assembly (9) comprises at least two positioning roller groups (91), and the two positioning roller groups (91) are located at the discharge end of the filler conveying belt (3) and are spaced apart along the conveying direction of the steel strip.

9. The drug core wire filler device of claim 5 or 8, wherein, The filler conveying belt (3) is provided with a material guiding part (10) below the discharge end, the material guiding part (10) comprises a support seat (101) and two vertical plates (102) arranged on the upper end face of the support seat (101), and the two vertical plates (102) are arranged in a spaced manner to form a limiting cavity for the steel belt to pass through.

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