Welding process of stay cable sheath

Abstract

The invention provides a welding process of a stay cable sheath, which relates to the technical field of welding processes and comprises the following steps: cleaning the surface of the sheath through a solvent to remove oil stains, oxides and impurities; the position of the sheath is accurately positioned, and a special clamp is used for fixing and aligning a welded butt joint port area; cutting the end surfaces of the two groups of sheaths through cutting equipment, and keeping the end surfaces flat; a hydraulic rod at the bottom is started, and one protective sleeve is pulled to be in butt joint with the other protective sleeve; by means of a driving mechanism, protrusions generated after welding are scraped to be flat, and the welding areas of the two protective sleeves are leveled; according to the method, after the two sheaths are clamped through the clamp, cutting, butt joint, heating and scraping leveling treatment can be directly conducted on the end faces, needing to be subjected to hot melting welding, of the inner sides, the sheaths do not need to be frequently rotated in the operation process, the machining efficiency is higher, the welded sheaths are in butt joint in order, and the welding quality is improved. And the stability is higher.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding process, in particular to a welding process of cable-stayed cable sheath. BACKGROUND

[0002] The cable-stayed cable sheath is an important protective component of the cable-stayed bridge cable system, which is usually made of high-density polyethylene (HDPE) and other materials, has the characteristics of anti-ultraviolet, corrosion resistance, impact resistance, etc. Its structure design often contains longitudinal slits and concave-convex embedded grooves, which facilitates wrapping the cable and forming a closed protective layer 1 during installation. The sheath enhances the warning effect through bright colors or reflective effect, while the internal multi-layer protection (such as PE sheath + corrosion-resistant grease) can effectively block moisture, salt mist and other corrosive media, prolonging the service life of the cable 57. Modern sheath technology also integrates fireproof, explosion-proof and other special functions. The installation of the cable-stayed cable sheath needs to be completed through the process of hot melt welding.

[0003] The existing technology for welding processing of the cable-stayed cable sheath needs to polish the end of the sheath first, then pull the butt joint, and then uniformly heat and melt the butt joint area through a heating assembly after the butt joint is completed, and then the welding processing can be completed through extrusion. The whole processing procedure is complicated, and the extrusion deformation and protrusion on the surface after welding still need to be cleaned up additionally. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application aims to provide a welding process of cable-stayed cable sheath to solve the problems raised in the background art. The present application can directly cut, butt joint, heat and scrape and flatten the end face that needs to be hot melt welded on the inside after clamping the two sheaths with a clamp, so the sheath does not need to be frequently rotated during the operation process, the processing efficiency is higher, and the butt joint of the sheath after welding is neat and has higher stability.

[0005] In order to achieve the above-mentioned purpose, the present application is realized by the following technical scheme: a welding process of cable-stayed cable sheath, comprising the following steps: S1, cleaning the surface of the sheath by solvent to remove oil stains, oxides and impurities; S2, accurately positioning the position of the sheath and fixing it with a special clamp for aligning the butt joint area for welding; S3, cutting the end face of the two sheaths with a cutting device to keep it flat, controlling the extension movement of the cutting mechanism to cut the end of the other sheath, starting the driving mechanism to control the circumferential movement of the cutting mechanism around the sheath during the cutting process, controlling the contraction of the cutting mechanism after cutting, and rotating the hand wheel to move the saw blade in the cutting mechanism away from the surface of the sheath; S4, start the hydraulic rod at the bottom, pull one of the sheaths to butt joint with the other sheath, apply the heating assembly to heat and melt the cut sheath end face for realizing material fusion welding, continue to increase the pressure of the hydraulic rod during the melting process to enhance the extrusion effect during butt joint; S5, flatten the protrusion generated after welding by means of the driving mechanism, and flatten the welding area of the two sheaths; S6, naturally or forcibly cool the welding part to eliminate stress concentration and deformation hazards.

[0006] Further, in step S1, a special solvent is used for wiping combined with fine sandpaper polishing until the roughness is Ra≤25μm, and the special solvent includes a non-polar solvent and a modified alcohol ether solvent.

[0007] Further, in step S2, two sets of clamps are used, one set of clamps is installed at the top end of the fixed plate, and the other set of clamps is installed at the top end of the movable plate, and the fixed plate and the movable plate are both arranged on the base, the bottom of the movable plate is embedded in the sliding groove opened in the base through the protruding block, and each sheath is directly inserted through the support sleeve on the inner side of the corresponding clamp and pressed on the surface of the support ring during clamping.

[0008] Further, after the sheath is supported by the support sleeve and the support ring, the fixed ring part is pressed vertically downward on the top of the sheath, and the bolt is used to pass through the fixed ring and the end of the support ring at the bottom to clamp and lock each sheath part, and a three-dimensional measuring instrument is used to accurately calibrate the butt joint position of the sheath, with an error controlled within ±0.5mm.

[0009] Further, it also includes the processing process of cutting the sheath: start the second motor in the cutting mechanism, rotate the second driving shaft through the second motor, the shell part of the second motor is sleeved on the guide rod through the sliding sleeve, the guide rod is directly embedded into one side of the rotating sleeve, after rotating the hand wheel, the guide rod controls the lifting movement of the whole cutting mechanism through the screw thread hole on the guide rod, until the saw blade part at the end is pressed to the surface of the sheath.

[0010] Further, after the saw blade contacts the sheath, the second motor is started to completely embed the saw blade into the inside of the sheath, and then the first motor is started to rotate through the first motor in the driving mechanism to drive the first driving shaft to rotate, the second driving shaft drives the first driving gear on the surface to rotate, the first driving gear and the second driven gear ring mesh, and then control the rotating movement of the whole rotating sleeve.

[0011] Further, after rotating the sleeve, the entire cutting mechanism is controlled to move circumferentially around the inner sheath, and the sheath is cut by rotating around the sheath. After cutting, the cutting mechanism is reset, the sliding sleeve is pulled along the guide rod, the saw blade is aligned with the surface of the other sheath, the hand wheel is turned again to press the saw blade, the cutting process of the other end of the sheath is realized, and after the cutting is completed, the hand wheel is turned in reverse to lift the saw blade and retract the saw blade to the shortest position. At this time, the sliding frame at the top of the hot melt welding mechanism is pulled, and the hot melt welding mechanism is set in the middle region of the two sheaths.

[0012] Further, in step S4, the hydraulic rod is started to abut the two sheaths inside the hot melt welding mechanism, the high-temperature gas flow generated by the hot air welding device is delivered to the inside of the hot air sleeve through the pipeline, and after the first motor is started, the first drive shaft is driven by the flat key to rotate the transmission pipeline, so that the second driven gear ring is rotated by the second driving gear at the end, and the hot air sleeve at the bottom is controlled to move circumferentially around the welding area.

[0013] Further, after the hot air sleeve rotates, the inner convex strip inside is controlled to rotate synchronously, the inner convex strip is pressed on the surface of the abutment region of the two sheaths, and after the extrusion force applied by the hydraulic rod between the two sheaths is increased, the inner convex strip is always scraped along the outside of the welding area and removes the softened material extruded during the hot melt welding process.

[0014] Further, in step S6, natural cooling is used for thin-walled sheaths with a wall thickness less than 10mm, and forced cooling is used for thick-walled sheaths with a wall thickness greater than or equal to 10mm. The forced cooling is assisted by air cooling with a wind speed ≤5m / s, and the cooling rate is controlled in the range of 2-5℃ / min. After cooling, the air tightness test is performed by the negative pressure detector.

[0015] The beneficial effects of the present application are: 1. The welding process of the cable sheath can directly cut, abut, heat and scrape and flatten the end face inside that needs to be hot melt welded after clamping the two sheaths by the clamp, the operation process does not need to frequently rotate the sheath, the processing efficiency is higher, and the abutted sheath after welding is neat and has higher stability.

[0016] 2. The welding process of the cable sheath supports the two sheaths by the welding device, and can directly cut a small amount around the contact end face after supporting, the size of the sawing device used is smaller, the stability is higher, the cutting process can be quickly realized, and after the cutting is completed, the cutting device does not need to be removed or the two sheaths do not need to be moved out, and the subsequent abutting process can be directly carried out.

[0017] 3. The welding process of the cable sheath is directly controlled by the driving mechanism to rotate the cutting mechanism and the hot melt welding mechanism, so that after butt joint is completed, the hot melt welding mechanism can be quickly switched to align with the end face to be welded, and hot melt welding processing is directly performed, and the surface protruding area can be scraped and flattened during welding. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 A flowchart of the welding process of the cable sheath of the present application; Figure 2 A device structure diagram for welding in the welding process of the cable sheath of the present application; Figure 3 A structure diagram of the clamp part of the present application; Figure 4 A structure diagram of the driving mechanism part of the present application; Figure 5 A structure diagram of the hot melt welding mechanism part of the present application; Figure 6 A structure diagram of the rotating sleeve part of the present application; Figure 7 A structure diagram of the cutting mechanism part of the present application; Figure 8 A connection diagram of the transmission pipeline part of the present application; In the figure: 1, base; 2, fixed plate; 3, movable plate; 4, sliding groove; 5, hydraulic rod; 6, support frame; 7, strip-shaped hole; 8, clamp; 9, driving mechanism; 10, rotating sleeve; 11, cutting mechanism; 12, hot melt welding mechanism; 13, support sleeve; 14, retainer ring; 15, fixed ring; 16, first motor; 17, first driving shaft; 18, first driving gear; 19, flat key; 20, transmission pipeline; 21, sliding frame; 22, sliding plate; 23, second driving gear; 24, hot air sleeve; 25, inner protruding strip; 26, second driven gear ring; 27, support ring; 28, butt joint sleeve ring; 29, first driven gear ring; 30, second motor; 31, second driving shaft; 32, saw blade; 33, sliding sleeve; 34, guide rod; 35, screw rod; 36, hand wheel. DETAILED DESCRIPTION

[0019] In order to make the technical means, creative features, purposes and effects achieved by the present application easy to understand, the present application will be further described below in combination with specific embodiments.

[0020] Please refer to Figures 1 to 8 The present application provides the following technical solutions: a welding process of a cable sheath, comprising the following steps: S1, clean the surface of the sheath by solvent to remove oil stains, oxides and impurities; The surface is polished with a special solvent and fine sandpaper until the roughness is Ra≤25μm. The special solvent includes non-polar solvents and modified alcohol ether solvents. S2. Accurately position the sheath and fix it with a special clamp 8 to align the welded joint area.

[0021] In this embodiment, a clamp 8 device is used. There are two clamps 8. A fixed plate 2 is welded to the surface of the base 1. A sliding groove 4 is also opened on the surface of the base 1. A movable plate 3 is inserted into the top of the sliding groove 4. The two clamps 8 are respectively installed on the top of the fixed plate 2 and the movable plate 3. Each clamp 8 includes a support sleeve 13, a support ring 14 and a fixing ring 15. The support ring 14 and the support sleeve 13 are integrally formed. The fixing ring 15 is screwed to the top of the support ring 14. A support frame 6 is welded to the top of both the fixed plate 2 and the movable plate 3. A strip hole 7 is opened on the top of the support frame 6. A first motor 16 is screwed to one end of the support frame 6.

[0022] Two sets of clamps 8 are used. One set of clamps 8 is installed on the top of the fixed plate 2, and the other set of clamps 8 is installed on the top of the movable plate 3. Both the fixed plate 2 and the movable plate 3 are set on the base 1. The bottom of the movable plate 3 is embedded into the sliding groove 4 opened on the base 1 through the protrusion. During the clamping process, each sheath is directly passed through the support sleeve 13 inside the corresponding clamp 8 and pressed on the surface of the support ring 14.

[0023] After the sheath is supported by the support sleeve 13 and the support ring 14, the fixing ring 15 is pressed vertically downward on the top of the sheath, and bolts are used to pass through the fixing ring 15 and the bottom support ring 14 to clamp and lock each part of the sheath. The docking position of the sheath is precisely calibrated using a three-dimensional measuring instrument, and the error is controlled within ±0.5mm. S3. The two sets of sheaths are cut using a cutting device to keep them flat. The cutting mechanism 11 is extended to cut the other sheath end. During the cutting process, the drive mechanism 9 is activated to control the cutting mechanism 11 to move in a circular motion around the sheath. After cutting, the cutting mechanism 11 is retracted, and the handwheel 36 is rotated to move the saw blade 32 in the cutting mechanism 11 away from the surface of the sheath. The welding equipment supports the two sets of sheaths and can directly perform micro-cutting around the contact end faces after support. The sawing equipment used is smaller in size, more stable, and can quickly complete the cutting process. After the cutting is completed, there is no need to remove the cutting equipment or directly remove the two sheaths; the subsequent docking process can be carried out directly.

[0024] The cutting mechanism 11 is used in the embodiment, a butt joint collar 28 is inserted on one side of the movable plate 3, one end of the butt joint collar 28 is integrally formed with a rotating sleeve 10, a first transmission gear ring is installed on the surface of the rotating sleeve 10, the cutting mechanism 11 comprises a second motor 30, a saw blade 32, a sliding sleeve 33 and a guide rod 34, one end of the guide rod 34 is inserted into the inside of the rotating sleeve 10, a threaded hole is formed on the surface of the guide rod 34, and a lead screw 35 is inserted into the inside of the threaded hole, a hand wheel 36 is welded at the top end of the lead screw 35, the lead screw 35 is outwardly threaded from the side of the rotating sleeve 10, the sliding sleeve 33 is sleeved on the surface of the guide rod 34, and locking screws are inserted into the side of the sliding sleeve 33, the output end of the second motor 30 is connected with a second driving shaft 31, and the end of the second driving shaft 31 is provided with the saw blade 32.

[0025] The second motor 30 in the cutting mechanism 11 is started, the second driving shaft 31 is driven to rotate by the second motor 30, the shell part of the second motor 30 is sleeved on the guide rod 34 by screwing the sliding sleeve 33, the guide rod 34 is directly embedded into one side of the rotating sleeve 10, after rotating the hand wheel 36, the guide rod 34 drives the whole cutting mechanism 11 to move up and down by cooperating with the threaded hole on the guide rod 34 through the lead screw 35, until the end of the saw blade 32 is pressed to the surface of the sheath.

[0026] After the saw blade 32 contacts the sheath, the second motor 30 is started, the saw blade 32 is completely embedded into the inside of the sheath by the second motor 30, and then the first motor 16 is started, the first motor 16 in the driving mechanism 9 is rotated to drive the first driving shaft 17 to rotate, the first driving shaft 17 drives the first driving gear 18 on the surface to rotate, the first driving gear 18 is engaged with the second driven gear ring 26, and then the whole rotating sleeve 10 is controlled to rotate.

[0027] After the rotating sleeve 10 rotates, the whole cutting mechanism 11 is controlled to move in a circle around the inside sheath, the sheath is cut by rotating around the sheath, after cutting, the cutting mechanism 11 is reset first, the sliding sleeve 33 is moved along the guide rod 34, the saw blade 32 is aligned with the surface of another sheath, the hand wheel 36 is rotated again to press the saw blade 32, the cutting process of the end of another sheath is realized, after the whole cutting is completed, the hand wheel 36 is reversely rotated to lift the saw blade 32, and the saw blade 32 is retracted to the shortest position, at this time, the sliding frame 21 at the top of the hot melt welding mechanism 12 is pulled, and the hot melt welding mechanism 12 is sleeved in the middle area of the two sheaths; S4, start the hydraulic rod 5 at the bottom, pull one of the sheaths and the other sheath to butt joint, apply the heating assembly to heat and melt the cut sheath end face, for realizing material fusion welding, continue to increase the pressure of the hydraulic rod 5 during the melting process, enhance the extrusion effect when butt joint, start the hydraulic rod 5 to butt joint the two sheaths inside the hot melt welding mechanism 12, the high temperature gas flow generated by the hot air welding equipment is transported to the inside of the hot air sleeve 24 through the pipeline, after starting the first motor 16, the first drive shaft 17 cooperates with the key 19 to drive the transmission pipeline 20 to rotate, so that the second driving gear 23 at the end drives the second driven gear ring 26 to rotate, ensuring that the bottom hot air sleeve 24 moves around the welding area.

[0028] The driving mechanism 9 is also used in this embodiment, the driving mechanism 9 includes the first motor 16, the first drive shaft 17 and the transmission pipeline 20, the output end of the first motor 16 is connected with the first drive shaft 17, the surface of the first drive shaft 17 is key connected with the first driving gear 18, the first driving gear 18 is engaged with the first driven gear ring 29, the end of the first drive shaft 17 is sleeved with the transmission pipeline 20, and the surface of the first drive shaft 17 is embedded with the key 19, and the outside of the key 19 is embedded into the inner wall of the transmission pipeline 20, the end of the transmission pipeline 20 passes through the side of the sliding frame 21, and the end of the transmission pipeline 20 is key connected with the first driving gear 18; S5, the driving mechanism 9 is used to scrape the protrusions generated after welding, and the welding area of the two sheaths is flattened.

[0029] The hot melt welding mechanism 12 is also used in this embodiment, the hot melt welding mechanism 12 includes the sliding frame 21, the support ring 27, the hot air sleeve 24 and the inner convex strip 25, the top end of the sliding frame 21 is integrally formed with the sliding plate 22, the bottom of the sliding frame 21 is integrally formed with the support ring 27, the side of the hot air sleeve 24 is provided with the second driven gear ring 26, the second driving gear 23 is engaged with the second driven gear ring 26, and the inner convex strip 25 is attached to the inside of the hot air sleeve 24, and the inner convex strip 25 is used to press on the surface of the sheath.

[0030] After the hot air sleeve 24 rotates, the inner convex strip 25 on the inside rotates synchronously, the inner convex strip 25 presses on the surface of the butt joint area of the two sheaths, after the extrusion force applied by the hydraulic rod 5 between the two sheaths is increased, the inner convex strip 25 always rotates and scrapes along the outside of the welding area, and removes the softened material extruded during the hot melt welding process; the driving mechanism 9 directly controls the cutting mechanism 11 and the hot melt welding mechanism 12 to rotate, so that after butt joint is completed, the hot melt welding mechanism 12 can be quickly switched to align with the end face that needs to be welded, and hot melt welding processing is directly performed, and the surface protrusion area can be scraped and flattened during welding.

[0031] S6, natural or forced cooling of the welded part, eliminating stress concentration and deformation hidden danger. Natural cooling is used for thin-walled sheath with wall thickness less than 10mm, forced cooling is used for thick-walled sheath with wall thickness greater than or equal to 10mm, the forced cooling is assisted by air cooling, the wind speed is less than or equal to 5m / s, and the cooling rate is controlled in the range of 2-5℃ / min, after the cooling is completed, the air tightness test is carried out by using negative pressure detector.

[0032] The above process can directly cut, butt, heat and scrape and flatten the end face of the inner side which needs to be hot melt welded after clamping the two sheaths by the clamp 8, the operation process does not need to frequently rotate the sheath, the processing efficiency is higher, and the butt joint of the welded sheath is neat and has higher stability.

[0033] The above shows and describes the basic principles and main features of the present application and the advantages of the present application, for those skilled in the art, it is obvious that the present application is not limited to the details of the above exemplary embodiments, and the present application can be realized in other specific forms without departing from the spirit or essential characteristics of the present application.

[0034] In addition, it should be understood that, although the present application is described in the form of embodiments, not every embodiment contains only one independent technical solution, the description manner of the specification is only for the sake of clarity, those skilled in the art should consider the specification as a whole, the technical solutions in each embodiment can also be combined appropriately to form other embodiments which can be understood by those skilled in the art.

Claims

1. A welding process for a stay cable sheath, characterized in that The method comprises the following steps: S1, cleaning the surface of the sheath by solvent to remove oil, oxide and impurities; S2, accurately positioning the sheath position, using special fixture to fix, for aligning the butt joint area of the welded sheath; S3, cutting the end face of the two groups of sheaths by cutting equipment, keeping flat, controlling the extension movement of the cutting mechanism, cutting the other end of the sheath, starting the driving mechanism to control the cutting mechanism to make circumferential movement around the sheath during the cutting process, controlling the contraction of the cutting mechanism after cutting, and rotating the hand wheel to move the saw blade in the cutting mechanism away from the surface of the sheath; S4, starting the hydraulic rod at the bottom, pulling one of the sheaths to butt joint with the other sheath, applying the heating assembly to heat and melt the cut end face of the sheath, for realizing material fusion welding, and continuously increasing the pressure of the hydraulic rod during the melting process to enhance the extrusion effect during butt joint; S5, scraping the protrusions generated after welding by the driving mechanism, and flattening the welding area of the two sheaths; S6, naturally or forcibly cooling the welded part to eliminate stress concentration and deformation hazards.

2. A welding process for a cable stay jacket as defined in claim 1, characterized in that: In step S1, special solvent wiping is combined with fine sandpaper polishing until the roughness is Ra≤25μm, and the special solvent includes non-polar solvent and modified alcohol ether solvent.

3. A welding process for a cable stay jacket as defined in claim 1, wherein: In step S2, two groups of clamps are used, one group of clamps is installed at the top end of the fixed plate, and the other group of clamps is installed at the top end of the movable plate, and the fixed plate and the movable plate are both arranged on the base, the bottom of the movable plate is embedded into the sliding groove on the base through the protrusion, and each sheath is directly inserted into the corresponding support sleeve on the inner side of the clamp during clamping, and pressed on the surface of the support ring.

4. A welding process for a cable stay jacket as defined in claim 3, wherein: After the sheath is supported by the support sleeve and the support ring, the fixed ring part is pressed vertically downward on the top of the sheath, and the bolts pass through the fixed ring and the end of the support ring at the bottom to clamp and lock each sheath part, and the butt joint position of the sheath is accurately calibrated by using a three-dimensional measuring instrument, and the error is controlled within ±0.5mm.

5. A welding process for a cable stay jacket as defined in claim 3, wherein It also includes the processing of cutting the sheath: starting the second motor in the cutting mechanism, rotating the second drive shaft through the second motor, the shell part of the second motor is sleeved on the guide rod through the threaded sleeve, the guide rod is directly embedded into one side of the rotating sleeve, after rotating the hand wheel, the guide rod controls the lifting movement of the whole cutting mechanism through the thread hole on the guide rod, until the end of the saw blade is pressed onto the surface of the sheath.

6. A welding process for a cable stay jacket as defined in claim 5, wherein: After the saw blade contacts the sheath, the second motor is started to completely embed the saw blade into the inside of the sheath, and then the first motor is started to rotate through the first motor in the driving mechanism, driving the first drive shaft to rotate, the first drive shaft drives the first driving gear on the surface to rotate, the first driving gear meshes with the second driven gear ring, and then controls the rotating movement of the whole rotating sleeve.

7. A welding process for a cable stay jacket as defined in claim 6, wherein: After rotating the rotating sleeve, the entire cutting mechanism is controlled to move circumferentially around the inner sheath. The sheath is cut by rotating around the sheath. After cutting, the cutting mechanism is first reset, the sliding sleeve is pulled to move along the guide rod, the saw blade is aligned with the surface of the other sheath, the hand wheel is rotated again to press the saw blade, the cutting process of the end of the other sheath is realized, after completing the cutting, the hand wheel is reversed to lift the saw blade, and the saw blade is retracted to the shortest position. At this time, the sliding frame at the top of the hot melt welding mechanism is pulled, and the hot melt welding mechanism is sleeved in the middle region of the two sheaths.

8. A welding process for a cable stay jacket as defined in claim 5, wherein: In step S4, the hydraulic rod is started to abut and connect the two sheaths inside the hot melt welding mechanism. The high-temperature gas flow generated by the hot air welding device is delivered to the inside of the hot air sleeve through the pipeline. After the first motor is started, the first drive shaft cooperates with the flat key to drive the transmission pipeline to rotate, so that the second driven gear ring is rotated by the second driving gear at the end, and the bottom hot air sleeve is ensured to move circumferentially around the welding area.

9. A welding process for a cable stay jacket as defined in claim 8, wherein: After the hot air sleeve rotates, the inner convex strip inside is controlled to rotate synchronously. The inner convex strip is pressed on the surface of the abutment region of the two sheaths. After the hydraulic rod increases the extrusion force between the two sheaths, the inner convex strip always rotates and scrapes along the outside of the welding area, and removes the softened material extruded during the hot melt welding process.

10. The process of claim 1, wherein: In step S6, natural cooling is used for thin-walled sheaths with a wall thickness less than 10 mm, and forced cooling is used for thick-walled sheaths with a wall thickness greater than or equal to 10 mm. The forced cooling is cooled by air cooling, the wind speed is ≤5 m / s, and the cooling rate is controlled in the range of 2-5 ℃ / min. After cooling, the air tightness test is carried out by the negative pressure detector.

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