Centrifuge disc body welding processing method based on full-automatic welding equipment

Abstract

This invention relates to the field of welding technology, specifically to a method for welding centrifuge discs using fully automated welding equipment. The method employs high-frequency induction brazing to weld centrifuge discs, concentrating heat in the contact area between the reinforcing ribs and the disc body. This uniform heat input significantly reduces thermal stress in the disc body, effectively preventing warping and deformation, and improving the disc body's forming accuracy and structural stability. Furthermore, during the solder melting process, the clamping components increase the clamping force on the reinforcing ribs, causing the molten solder to flow from the center outwards under capillary action, fully filling the gap between the reinforcing ribs and the disc body, achieving a tight connection, reducing the probability of voids in the weld seam, improving the disc body's appearance quality, and extending its service life.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and specifically to a method for welding centrifuge discs based on fully automated welding equipment. Background Technology

[0002] Disc centrifuges, as core equipment for efficient separation of heterogeneous systems such as solid-liquid and liquid-liquid, rely on the theory of supergravity sedimentation and shallow pools. Compared with traditional separation machinery, they can not only obtain solid products with low moisture content and high-purity liquid products, but also have significant advantages such as continuous operation, automatic remote control, safe and reliable operation, small footprint and labor saving. They have been widely used in key industries such as chemical, petroleum, food and pharmaceutical, and have become important equipment to ensure production efficiency and product quality.

[0003] The core working component of a disc centrifuge consists of multiple coaxially mounted discs. The specific flow space formed between adjacent discs is the key area for material separation. To improve the structural strength of the discs and prevent deformation or damage due to centrifugal force under high-speed rotation, reinforcing ribs are welded to the outside of the discs to enhance their load-bearing capacity and service life.

[0004] Currently, laser welding is the most common method used in the industry for welding the reinforcing ribs of discs. However, laser welding often results in uneven weld points with high surface roughness, which not only affects the appearance quality of the discs but may also cause material to accumulate at the weld points during subsequent use, interfering with the separation effect. Furthermore, uneven heat distribution during laser welding can lead to localized high temperatures that cause thermal stress on the discs, resulting in problems such as warping and deformation. This severely reduces the forming accuracy and structural stability of the discs and may even lead to breakage of the discs at high speeds due to stress concentration, thus restricting the overall performance and reliability of disc centrifuges. Summary of the Invention

[0005] This invention provides a centrifuge disc welding method based on fully automated welding equipment, which solves the problems of uneven weld points and uneven heat distribution during the welding of reinforcing ribs in existing discs using laser welding, which affects the disc forming quality.

[0006] The centrifuge disc welding method based on fully automated welding equipment of the present invention adopts the following technical solution: A centrifuge disc welding method based on fully automated welding equipment includes the following steps:

[0007] S10, mount the disc body on the worktable;

[0008] S20, the reinforcing rib is placed at a preset welding position on the outer peripheral wall of the disc body, and the reinforcing rib is clamped by the clamping assembly, and brazing filler metal is placed between the disc body and the reinforcing rib.

[0009] S30, align the induction coil of the high-frequency induction brazing machine with one of the preset welding positions, and start the high-frequency induction brazing machine to melt the brazing filler metal. At the same time, the clamping force between the reinforcing rib and the disc body is increased by the clamping assembly.

[0010] S40 causes the disc to rotate around its own axis, changing the preset welding position aligned with the induction coil.

[0011] Furthermore, in step S10, a support frame is provided on the worktable to support the disc body.

[0012] Furthermore, the support frame includes a main frame and multiple support rods. The main frame is mounted on the workbench, and the multiple support rods are evenly distributed on the main frame. The disc body is a conical shell with both ends through in the axial direction. The disc body is placed on the multiple support rods, and the support rods are in contact with the inner peripheral wall of the disc body.

[0013] Furthermore, the main frame is mounted on the workbench via a motor.

[0014] Furthermore, in step S20, the reinforcing rib has a curved structure, and the curvature of the reinforcing rib is greater than that of the disc body. The reinforcing rib has a groove in the middle for placing the brazing filler metal.

[0015] Furthermore, there are multiple preset welding positions, which are evenly distributed in the circumferential direction of the disc body.

[0016] Furthermore, the clamping assembly includes multiple clamping rods, each corresponding to a support rod, and the clamping rods are movably mounted on their corresponding support rods along the radial direction of the disc body.

[0017] Furthermore, in step S30, in the initial state, the induction coil is positioned away from the disc body, and the induction coil can move towards the side closer to the disc body so that the induction coil is aligned with the lower end of the disc body.

[0018] Furthermore, the busbar at the lower end of the disc body is set in a horizontal direction.

[0019] Furthermore, the induction coil is connected to the brazing system of the high-frequency induction brazing machine via an electrode plate, and the electrode plate can slide on the worktable.

[0020] The beneficial effects of this invention are as follows: The centrifuge disc welding method based on fully automated welding equipment uses high-frequency induction brazing to weld the centrifuge discs, concentrating heat in the contact area between the reinforcing ribs and the disc body. This avoids the localized high temperatures caused by uneven heat distribution in traditional laser welding. The uniform heat input significantly reduces the thermal stress of the disc body, effectively preventing warping and deformation, and improving the disc body's forming accuracy and structural stability. Furthermore, during the solder melting process, the clamping components increase the clamping force on the reinforcing ribs, causing the molten solder to flow from the center outwards under capillary action, fully filling the gap between the reinforcing ribs and the disc body, achieving a tight connection, reducing the probability of porosity in the weld seam, and resulting in smoother and flatter weld points on the reinforcing ribs after welding, significantly reducing surface roughness, improving the disc body's appearance quality, and extending its service life. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 A flowchart illustrating an embodiment of the centrifuge disc welding method based on fully automated welding equipment of the present invention;

[0023] Figure 2 A schematic diagram of a welding device used to implement the centrifuge disc welding method based on a fully automated welding device according to the present invention;

[0024] Figure 3 for Figure 2 Front view of the middle section structure;

[0025] Figure 4 for Figure 3 A cross-sectional view along the AA direction;

[0026] Figure 5 for Figure 2 Side view of the middle section structure;

[0027] Figure 6 for Figure 5 A cross-sectional view along the BB direction;

[0028] Figure 7 for Figure 6 Enlarged view of point C in the middle;

[0029] Figure 8 for Figure 2A schematic diagram of the middle disc body and reinforcing ribs;

[0030] Figure 9 for Figure 2 A schematic diagram of the reinforcing ribs.

[0031] In the diagram: 100, disc body; 200, worktable; 210, support frame; 211, main frame; 212, support rod; 220, motor; 300, reinforcing rib; 310, brazing filler metal; 320, groove; 400, clamping assembly; 410, clamping rod; 411, mounting section; 412, clamping section; 500, robotic arm; 600, induction coil; 610, electrode plate. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] An embodiment of the centrifuge disc welding method based on fully automated welding equipment of the present invention is as follows: Figures 1 to 9 As shown.

[0034] The centrifuge disc body welding processing method based on fully automated welding equipment includes the following steps:

[0035] S10, Install the disc body 100 on the worktable 200.

[0036] S20, the reinforcing rib 300 is placed at a preset welding position on the outer peripheral wall of the disc body 100, and the reinforcing rib 300 is clamped by the clamping assembly 400, with brazing filler metal 310 placed between the disc body 100 and the reinforcing rib 300. Specifically, the reinforcing rib 300 is placed on the outer peripheral wall of the disc body 100 by a robot arm 500. The robot arm 500 is mounted on the worktable 200. There are multiple preset welding positions, which are evenly distributed in the circumferential direction of the disc body 100.

[0037] S30, align the induction coil 600 of the high-frequency induction brazing machine with one of the preset welding positions, and start the high-frequency induction brazing machine to melt the brazing filler metal 310. At the same time, the clamping force between the reinforcing rib 300 and the disc body 100 is increased by the clamping assembly 400.

[0038] Specifically, the high-frequency induction brazing machine is existing technology, including a brazing system and an induction coil 600. The brazing system is installed on the worktable 200. The brazing system is used to provide high-frequency alternating current to the induction coil 600 and generate eddy currents between the disc body 100 and the reinforcing rib 300. The brazing filler metal 310 is melted by the resistance heating effect and the gap between the reinforcing rib 300 and the disc body 100 is filled by the capillary principle, thereby achieving a firm connection between the reinforcing rib 300 and the disc body 100.

[0039] S40, rotate the disc body 100 around its own axis to change the preset welding position aligned with the induction coil 600. After welding, move the welded reinforcing rib 300 away from the induction coil 600 to avoid interference from external forces on the newly welded weld, ensuring welding strength. This also allows other parts of the disc body 100 that require welding reinforcing ribs 300 to be rotated to align with the induction coil 600 for welding again.

[0040] This embodiment employs high-frequency induction brazing to weld the centrifuge disc body 100. This concentrates heat in the contact area between the reinforcing rib 300 and the disc body 100, avoiding the localized high temperatures caused by uneven heat distribution in traditional laser welding. The uniform heat input significantly reduces the thermal stress of the disc body 100, effectively preventing warping and deformation, and improving the forming accuracy and structural stability of the disc body 100. Furthermore, during the melting process of the brazing filler metal 310, the clamping component 400 increases the clamping force on the reinforcing rib 300, causing the molten brazing filler metal 310 to flow from the center outwards under capillary action, fully filling the gap between the reinforcing rib 300 and the disc body 100, achieving a tight connection between the two, reducing the probability of voids in the weld seam, and resulting in smoother and flatter weld points on the reinforcing rib 300 after welding, significantly reducing surface roughness, improving the appearance quality of the disc body 100, and extending its service life.

[0041] Furthermore, in step S10, a support frame 210 is provided on the worktable 200, which is used to support the disc body 100.

[0042] The support frame 210 includes a main frame 211 and multiple support rods 212. The main frame 211 is mounted on the worktable 200 via a motor 220, and the multiple support rods 212 are evenly distributed on the main frame 211. The disc body 100 is a conical shell with both ends through in the axial direction. The disc body 100 is placed on the multiple support rods 212, and the support rods 212 are in contact with the inner peripheral wall of the disc body 100.

[0043] The disc body 100 is supported and positioned by multiple support rods 212, and the motor 220 can drive the disc body 100 to rotate around its own axis through the support frame 210.

[0044] Furthermore, in step S30, in the initial state, the induction coil 600 is positioned away from the disc body 100, and the induction coil 600 can move towards the side closer to the disc body 100, so that the induction coil 600 is aligned with the lower end of the disc body 100.

[0045] When installing the disc body 100, the induction coil 600 is positioned away from the disc body 100 to avoid interference during installation. After the disc body 100 is installed on the support frame 210, the induction coil 600 is moved closer to the disc body 100 to align with the preset welding position.

[0046] The induction coil 600 is connected to the brazing system via the electrode plate 610, and the electrode plate 610 can slide on the worktable 200 through the linkage controlled by the PLC program.

[0047] Specifically, the induction coil 600 includes a first segment, a last segment, and a coil segment. One end of the first segment is connected to the electrode plate 610, and the other end is connected to the coil segment, which is S-shaped. The other end of the coil segment is connected to the last segment, and the other end of the last segment is connected to the electrode plate 610. The coil segment includes three straight segments and two curved segments, with the two curved segments located between the three straight segments, making the coil segment as a whole S-shaped. For ease of explanation, the three straight segments arranged vertically in the coil segment are referred to as the first segment, the second segment, and the third segment, respectively. The first segment, the second segment, and the third segment are arranged vertically in sequence, with the first segment located above the second segment. It should be noted that when installing the induction coil 600, the spacing between the two coil segments corresponding to the welding position, i.e., the spacing between the second segment and the third segment, should be smaller than the spacing between the first segment and the second segment, to reduce the negative impact of the magnetic field and prevent uneven heat generation.

[0048] Furthermore, the busbar at the lower end of the disc body 100 is arranged in a horizontal direction. Taking advantage of the heavy nature of the molten solder 310 and the light nature of the gas, during the welding process, the gas generated between the reinforcing rib 300 and the disc body 100 can be smoothly discharged from bottom to top. Furthermore, the vibration generated during the clamping process by the clamping assembly 400 further reduces the probability of voids forming in the weld gap between the reinforcing rib 300 and the disc body 100.

[0049] Furthermore, in step S20, the reinforcing rib 300 has a curved surface structure, and the curvature of the reinforcing rib 300 is greater than the curvature of the disc body 100. The reinforcing rib 300 has a groove 320 in the middle for placing the brazing filler metal 310.

[0050] The clamping assembly 400 includes multiple clamping rods 410, each corresponding to a support rod 212. The clamping rods 410 are connected to the brazing system and are controlled by a PLC program to move along the radial direction of the disc body 100 while being mounted on their corresponding support rods 212. A welding space is defined between the clamping rods 410 and their corresponding support rods 212, and the location of this welding space is the preset welding position.

[0051] During the welding process, the clamping rod 410 is controlled by the brazing system to slide along the radial direction of the disc body 100 towards the side closer to the support rod 212, thereby increasing the clamping force on the reinforcing rib 300. This allows gas between the reinforcing rib 300 and the disc body 100 to be continuously discharged, and ensures that the molten brazing filler metal 310 fills the gap between the reinforcing rib 300 and the disc body 100, enhancing the welding strength. Furthermore, to ensure welding quality, after welding is completed, the clamping rod 410 continues to hold the weld for 8 to 10 seconds.

[0052] Specifically, the clamping rod 410 includes an mounting section 411 and a clamping section 412. The mounting section 411 is slidably mounted on the support rod 212, and the clamping section 412 is rotatably mounted on the support rod 212 via a rotating shaft. The clamping section 412 is connected to the brazing system and is controlled by a PLC program to rotate relative to the mounting section 411. When installing the disc body 100, the clamping section 412 rotates relative to the mounting section 411 to facilitate the installation of the disc body 100 on the support rod 212. After the disc body 100 is installed, the clamping section 412 is reversed and reset.

[0053] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for welding centrifuge discs based on fully automated welding equipment, characterized in that: Includes the following steps: S10, mount the disc body on the worktable; S20, the reinforcing rib is placed at a preset welding position on the outer peripheral wall of the disc body, and the reinforcing rib is clamped by the clamping assembly, and brazing filler metal is placed between the disc body and the reinforcing rib. S30, align the induction coil of the high-frequency induction brazing machine with one of the preset welding positions, and start the high-frequency induction brazing machine to melt the brazing filler metal. At the same time, the clamping force between the reinforcing rib and the disc body is increased by the clamping assembly. S40, causing the disc body to rotate around its own axis, changing the preset welding position aligned with the induction coil; In step S10, a support frame is provided on the worktable to support the disc body; The support frame includes a main frame and multiple support rods. The main frame is mounted on the workbench, and the multiple support rods are evenly distributed on the main frame. The disc body is a conical shell with both ends through in the axial direction. The disc body is placed on the multiple support rods, and the support rods are in contact with the inner peripheral wall of the disc body. The main frame is mounted on the workbench via a motor. In step S20, the reinforcing rib has a curved structure, and the curvature of the reinforcing rib is greater than that of the disc body. The reinforcing rib has a groove in the middle for placing the brazing filler metal. There are multiple preset welding positions, which are evenly distributed in the circumferential direction of the disc body; The clamping assembly includes multiple clamping rods, each corresponding to a support rod. The clamping rods are movably mounted on their corresponding support rods along the radial direction of the disc body.

2. The centrifuge disc welding method based on fully automated welding equipment according to claim 1, characterized in that: In step S30, the induction coil is initially positioned away from the disc body, and the induction coil can move towards the side closer to the disc body so that the induction coil is aligned with the lower end of the disc body.

3. The centrifuge disc welding method based on fully automated welding equipment according to claim 2, characterized in that: The busbar at the lower end of the disc body is set in a horizontal direction.

4. The centrifuge disc welding method based on fully automated welding equipment according to claim 2, characterized in that: The induction coil is connected to the brazing system of the high-frequency induction brazing machine through an electrode plate, and the electrode plate can slide on the worktable.

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