Flexible variable-diameter induction coil device suitable for pipe fitting brazing and welding method of flexible variable-diameter induction coil device

Abstract

The invention discloses a flexible variable-diameter induction coil device suitable for pipe fitting brazing and a welding method of the flexible variable-diameter induction coil device. The device comprises a coil body, a tensioning rope, a tensioning mechanism, a coil clamping assembly, a support and a power supply frame, and the coil body is provided with an opening ring part used for heating a workpiece and two tying parts; the two ends of the tensioning rope are correspondingly connected with the two tying parts respectively; the tensioning mechanism acts on the tensioning rope and promotes the opening ring part to deform through the tying part, so that the inner diameter of the opening ring part is flexible and controllable, and the welding requirements of pipe fittings with different diameters are met; the support provides a mounting base for the tensioning mechanism and the coil clamping assembly, and a cooling water path is arranged in the support, so that local overheating is avoided; the welding method comprises the steps of coil diameter adjustment, pipe fitting surface pretreatment, brazing filler metal configuration, clamping and positioning, electric heating, cooling and the like, and uniform heating and stable forming of a welding seam can be achieved. The device is compact in structure and wide in application range, and the brazing efficiency and the welding quality of the large-diameter pipe fitting can be remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of induction brazing, in particular to a flexible variable-diameter induction coil device suitable for pipe brazing and a brazing method thereof. BACKGROUND

[0002] Induction brazing is a common pipe connection method, and currently mainly adopts a circular closed type or a U-shaped semi-open type induction coil for heating. The closed type coil can obtain a relatively uniform temperature field, but has the defect that the workpiece is difficult to be sleeved or taken out during long pipe welding. The semi-open type coil is convenient for clamping and positioning of long pipes, but can only heat the pipe on one side, and is usually only suitable for small-diameter pipes with good heat conduction performance. With the wide application of large-diameter pipes in the fields of aerospace, energy power, chemical metallurgy and nuclear industry, the welding quality has become an important factor affecting the service life and operation safety of equipment. Large-diameter pipes have large size and heavy weight, which puts higher requirements on the structural design and cooling performance of induction heating equipment, especially the adaptability and durability of the heating coil.

[0003] Most of the existing induction heating coils are of integral or fixed structure, and the inner diameter is not adjustable, so the application range is limited. When the diameter of the pipe changes, the coil needs to be redesigned or processed, which not only increases the manufacturing cost, but also has poor versatility. At the same time, the integral coil needs to pass the workpiece from the inside of the coil during clamping, which is not convenient for large-diameter and long-size pipes, and is easy to cause the heating area to deviate, thereby affecting the welding precision and the quality of the finished product. In addition, the cooling design of the existing coil is mostly single channel, and the heat dissipation efficiency is insufficient, which is easy to cause local overheating under high-frequency heating conditions, resulting in material ablation or failure and shortening the service life. The connection between the power supply part and the coil also has the problem of insufficient insulation protection. When the gap is too small or the cooling is not sufficient, short circuit or arc discharge may occur, affecting the stability of the welding process and causing damage to the workpiece.

[0004] Chinese patent CN106392230A discloses an induction brazing system and method, which widens the size range of the coil and improves the versatility of the system, but does not provide a cooling channel, which is difficult to meet the demand of long-time high-frequency heating.

[0005] Chinese patents CN114871526A and CN110587051A both disclose openable and closable induction coils, which can be opened and closed multiple times, but their structures are complex, the clamping and disengaging efficiency is low, and there is no independent cooling design, which makes it difficult to guarantee the stability and durability of the coil under repeated opening and closing and high temperature. It can be seen that the existing induction heating coil still has obvious deficiencies in diameter adaptability, cooling efficiency and clamping convenience, and it is difficult to meet the requirements of high efficiency, high reliability and long service life for large-diameter pipe brazing.

[0006] Therefore, how to provide a flexible variable diameter induction coil device suitable for pipe brazing and a welding method thereof is a problem to be solved by those skilled in the art. SUMMARY

[0007] Therefore, the present application provides a flexible variable diameter induction coil device suitable for pipe brazing and a welding method thereof, which can adjust the caliber size of the working part of the induction coil according to the welding working condition, is convenient to clamp, is equipped with a cooling function, and improves the service life of the coil.

[0008] In order to achieve the above-mentioned purpose, the present application adopts the following technical scheme: a flexible variable diameter induction coil device suitable for pipe brazing, comprising:

[0009] A coil body is provided with an open ring part for heating a workpiece, and the two ends of the coil body corresponding to the open ring part are respectively extended with a draw-in part;

[0010] A tension rope is provided, and the two ends of the tension rope are respectively connected to the two draw-in parts;

[0011] A tensioning mechanism acts on the tension rope and causes the open ring part to deform through the draw-in part;

[0012] A coil clamping assembly acts on the draw-in part and guides the sliding of the draw-in part;

[0013] A support provides a mounting basis for the tensioning mechanism and the coil clamping assembly, and a cooling water channel is provided in the support, which is used for cooling the coil clamping assembly and the coil body;

[0014] A power supply frame is provided on the support and is in contact with the draw-in part for conduction.

[0015] The beneficial technical effects of the present application are: the open ring part provided by the coil body is actually the working area for heating the pipe, which can deform by the action of the tension rope and the tensioning mechanism. It can be understood that the caliber size of the open ring part can be appropriately adjusted according to the size of the workpiece to be welded, which has a wide range of applications, significantly improves the versatility and production efficiency of the coil, avoids the disadvantages of redesigning or processing the coil due to the change of the diameter of the pipe, integrates an independent cooling water channel in the support to form a high-efficiency circulating cooling structure, which can effectively suppress local overheating, prevent material ablation or failure, prolong the service life of the coil, and ensure the stability and continuity of the welding process.

[0016] Preferably, it further comprises a straightening rod, which is placed in the open ring part and limits the deformation caliber of the open ring part.

[0017] The technical effect produced thereby is that the orthopedic rod can assist in the orthopedic correction of the coil split ring part. It can be understood that, based on the support and limitation of the orthopedic rod, the split ring part can change in size in cooperation with the tensioning mechanism and the tensioning rope. In specific implementation, when the size of the split ring part increases, the split ring part needs to be manually adjusted, and when the size of the split ring part decreases, the tensioning mechanism and the orthopedic rod are relied on to achieve the adjustment.

[0018] Preferably, the coil body is formed by stacking multiple copper sheets, and the split ring part corresponding to the coil body is located on the outer side of the support.

[0019] The technical effect produced thereby is that the coil body is formed by stacking copper sheets, which has good electrical conductivity and deformation conditions, thereby meeting the subsequent requirement of changing the size of the split ring part.

[0020] Preferably, the tensioning mechanism comprises a winding wheel, a screw rod seat, a screw rod, and a stop block. The two groups of winding wheels and the screw rod seat are arranged on the side of the support close to the tensioning rope. The screw rod is threadedly connected to the screw rod seat. The stop block is arranged at the end of the screw rod close to the tensioning rope. The axial displacement of the screw rod causes the stop block to change the pulling state of the tensioning rope.

[0021] The technical effect produced thereby is that the tensioning mechanism uses the winding wheel and the screw rod to support the tensioning rope and adjusts the pulling state of the tensioning rope based on the axial movement of the screw rod.

[0022] Preferably, the coil clamping assembly comprises a guide wheel, an insulating partition plate, and a partition plate seat. The two guide wheels are arranged on the side of the support close to the split ring part. The two groups of guide wheels are arranged on the outer side of the two draw-in parts. The insulating partition plate is fixedly connected to the support through the partition plate seat. The insulating partition plate is provided with two parallel channel grooves for clamping the two draw-in parts.

[0023] The technical effect produced thereby is that the coil clamping assembly can guide and clamp the sliding of the draw-in part based on the insulating partition plate, thereby ensuring the stable pulling of the draw-in part.

[0024] Preferably, the support further comprises a water inlet nozzle and a water outlet nozzle. The two side walls of the support are respectively provided with a water inlet and a water outlet corresponding to the two ends of the cooling water channel. The water inlet nozzle is detachably connected to the water inlet, and the water outlet nozzle is detachably connected to the water outlet.

[0025] The technical effect produced thereby is that the water inlet nozzle and the water outlet nozzle are connected to the external water system and the cooling water channel, thereby establishing a cooling cycle, effectively inhibiting local overheating, preventing material ablation or failure, prolonging the service life of the coil, and ensuring the stability and continuity of the welding process.

[0026] Preferably, the power supply frame is rotationally connected with a conductive wheel, the conductive wheel rolls and presses the connecting part, the bottom side of the power supply frame is provided with an insulating seat, and the insulating seat is fixedly connected with the support.

[0027] The technical effect generated thereby is that the power supply frame is connected with the coil through the conductive wheel, and the insulating seat is used for insulating and isolating the conductive frame and the support, thereby ensuring electrical insulation safety.

[0028] Preferably, the tensioning rope is formed of carbon fiber material.

[0029] The technical effect generated thereby is that the tensioning rope is insulating and has strong tensile capacity.

[0030] Preferably, the conductive wheel and the power supply frame are both made of pure copper material.

[0031] Preferably, the insulating partition plate and the insulating seat are made of bakelite or insulating ceramic.

[0032] The technical effect generated thereby is that high-conductivity pure copper conductive components are adopted, combined with the bakelite or insulating ceramic partition plate, which has excellent conductive performance and ensures electrical insulation safety, avoids short circuit and arc discharge risk, and thus improves welding quality and operation reliability.

[0033] The device has compact overall structure, small size, is convenient to operate and clamp, can effectively solve the problems of difficult clamping before welding, uneven welding temperature field and difficult withdrawal after welding of large-diameter pipe fittings, and improves the applicability and stability of the welding process.

[0034] The application further discloses a welding method of the flexible variable-diameter induction coil suitable for pipe fitting brazing, and the welding method uses the induction coil device.

[0035] S1: the diameter of the split ring part is adjusted, and a straightening rod matched with the diameter of the pipe fitting to be welded is used to straighten the split ring part.

[0036] S2: the surface of the pipe fitting welding area is pretreated, including oil removal, rust removal and alcohol cleaning.

[0037] S3: brazing filler metal paste is uniformly applied or a brazing filler metal ring is placed at the pipe fitting to be welded.

[0038] S4: the pipe fitting to be welded is clamped by using external equipment, so that the welding area is located at the center of the annular split ring part and is matched with the inner wall of the annular split ring part.

[0039] S5: process parameters are set, induction brazing is performed, and the cooling water channel continues to flow until the temperature drops to a safe range after welding.

[0040] The beneficial effects of the present application are: the method comprehensively considers the structure characteristics of the large-diameter pipe fitting and the problem of uneven temperature field in the welding process, a flexible variable-diameter induction coil is proposed, which better meets the industrial manufacturing requirements, has wide industrial application prospects, the variable-diameter induction coil not only makes the large-diameter pipe fitting obtain a uniform temperature field in the welding process, but also solves the problem that the large-diameter pipe fitting is difficult to enter and exit, and the induction brazing of the pipe joint has very important significance and wide industrial application prospects.

[0041] The welding method using the flexible variable-diameter induction coil for induction brazing can conveniently and efficiently obtain a large-diameter pipe fitting welding joint with stable forming quality.

[0042] Preferably, the diameter of the orthopedic rod in step S1 is 0.5mm-2mm larger than the diameter of the pipe fitting.

[0043] The technical effect generated thereby is to avoid short-circuiting the pipeline and ensure a smooth induction heat welding process.

[0044] Preferably, the pipe fitting joint in step S2 is in a sleeved form.

[0045] The technical effect generated thereby is that the sleeved form can improve the stability of the welding area of adjacent pipe fittings and is not prone to breaking. BRIEF DESCRIPTION OF DRAWINGS

[0046] Fig. 1 The structure diagram of the flexible variable-diameter induction coil device suitable for pipe fitting brazing of the present application;

[0047] Fig. 2 The cooling water path schematic diagram of the flexible variable-diameter induction coil device suitable for pipe fitting brazing of the present application;

[0048] Fig. 3 The flowchart of the welding method of the present application.

[0049] 1 coil body, 11 open ring part, 12 pull part, 2 tensioning rope, 3 tensioning mechanism, 31 winding direction wheel, 32 screw rod seat, 33 screw rod, 34 abutting block, 4 coil clamping assembly, 41 guide wheel, 42 insulation partition, 43 partition seat, 5 support, 51 cooling water path, 52 water inlet nozzle, 53 water outlet nozzle, 6 power supply rack, 7 orthopedic rod, 8 conductive wheel, 9 insulation seat. DETAILED DESCRIPTION

[0050] 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 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.

[0051] Referring to the drawings of the present application Figs. 1 to 3 According to the embodiment of the present application, a flexible variable diameter induction coil device suitable for pipe brazing comprises:

[0052] A coil body 1 is provided with an open ring part 11 for heating workpieces, and the coil body 1 extends with two pull-in parts 12 at both ends corresponding to the open ring part 11, and the two pull-in parts have parallel sections;

[0053] A tensioning rope 2 is provided with two ends corresponding to the two pull-in parts 12 respectively, and the tensioning rope 2 forms an irregular loop with the coil body;

[0054] A tensioning mechanism 3 acts on the tensioning rope 2 and promotes the deformation of the open ring part 11 through the pull-in parts 12, facilitating the subsequent straightening process;

[0055] A coil clamping assembly 4 acts on the pull-in parts 12 and guides the sliding of the pull-in parts 12, and the coil clamping assembly 4 has a guiding pulling effect;

[0056] A support 5 provides a mounting basis for the tensioning mechanism 3 and the coil clamping assembly 4, and the support 5 is provided with a cooling water channel 51 inside, which is used for cooling the coil clamping assembly and the coil body 1 to avoid local overheating;

[0057] A power supply frame 6 is arranged on the support 5 and in contact with the pull-in parts 12 for conduction.

[0058] In other embodiments, a straightening rod 7 is also included, which is placed in the open ring part 11 and limits the deformation diameter of the open ring part 11, and the deformation of the open ring part is precisely controlled by means of the straightening rod 7.

[0059] In other specific embodiments, the coil body 1 is formed by stacking multiple copper sheets, which is arranged vertically to the support, and the corresponding open ring part 11 of the coil body 1 is located outside the support 5, avoiding space for subsequent pipe welding.

[0060] In other embodiments, the tensioning mechanism 3 includes a winding wheel 31, a screw rod seat 32, a screw rod 33, and an abutting block 34, the winding wheel 31 has two groups, the two groups of winding wheels 31 and the screw rod seat 32 are arranged on one side of the support 5 close to the tensioning rope 2, the screw rod 33 is threadedly connected to the screw rod seat 32, the abutting block 34 is arranged at one end of the screw rod 33 close to the tensioning rope 2, the axial displacement of the screw rod 33 causes the abutting block 34 to change the pulling state of the tensioning rope 2, the abutting block 34 rotates at the end of the screw rod, and the abutting block 34 has an arc surface matched with the tensioning rope 2.

[0061] In some other embodiments, the coil clamping assembly 4 comprises guide wheels 41, an insulating partition 42 and a partition base 43, the guide wheels 41 are rotatably arranged in pairs on one side of the support 5 close to the opening ring part 11, and the two pairs of guide wheels 41 are arranged outside the two tie parts, the insulating partition 42 is fixedly connected to the support 5 through the partition base 43, and the insulating partition 42 is provided with two parallel arranged channel grooves for clamping the two tie parts 12.

[0062] In some other embodiments, the water inlet nozzle 52 and the water outlet nozzle 53 are further included, the two side walls of the support 5 are respectively provided with water inlets and water outlets corresponding to the two ends of the cooling water channel 51, the water inlet nozzle 52 is detachably connected to the water inlet, and the water outlet nozzle 53 is detachably connected to the water outlet.

[0063] In some other embodiments, the power supply frame 6 is rotatably connected with a conductive wheel 8, the conductive wheel 8 rolls against the tie part 12, and the bottom side of the power supply frame 6 is provided with an insulating base 9 fixedly connected to the support 5.

[0064] In some other embodiments, the tensioning rope 2 is formed of carbon fiber material.

[0065] The conductive wheel and the power supply frame are both made of pure copper material, and the insulating base 9 and the insulating partition 42 are made of bakelite or insulating ceramic. The high-conductivity pure copper conductive part is combined with the bakelite or insulating ceramic partition, so that excellent conductivity performance is achieved, the safety of electrical insulation is ensured, the risks of short circuit and arc discharge are avoided, and the welding quality and operation reliability are improved.

[0066] The device comprehensively considers the structure characteristics of the large-diameter pipe and the problem of uneven temperature field in the welding process, and proposes a flexible variable-diameter induction coil, which better meets the industrial manufacturing requirements and has wide industrial application prospects.

[0067] The application further discloses a welding method suitable for the flexible variable-diameter induction coil for pipe brazing, and the method uses the induction coil device and comprises the following steps.

[0068] S1: adjusting the diameter of the opening ring part, and adopting a straightening bar matched with the diameter of the pipe to be welded to straighten the opening ring part;

[0069] S2: performing surface pretreatment on the pipe welding area, including oil removal, rust removal and alcohol cleaning;

[0070] S3: uniformly applying brazing paste or placing a brazing ring at the pipe welding position;

[0071] S4: clamping the pipe to be welded by using external equipment, so that the welding area is located at the center of the annular opening part and is matched with the inner wall of the annular opening part with a suitable gap;

[0072] S5: setting process parameters, energizing for induction brazing, and continuing to maintain the flow of cooling water after welding until the temperature drops to a safe range.

[0073] Specifically, the diameter of the orthopedic rod in step S1 is 0.5mm-2mm larger than the diameter of the pipe.

[0074] Further, the joint of the pipe in step S2 is in a sleeving form, which can improve the welding quality and stability of the pipe.

[0075] In the present application, the variable-diameter induction coil not only makes the large-diameter pipe obtain a uniform temperature field during welding, but also solves the problem of difficult entry and exit of the large-diameter pipe. The promotion and application of induction brazing of pipe joints have great significance, and the industrial application prospect is wide.

[0076] For the device and use method disclosed in the embodiments, since they correspond to the method disclosed in the embodiments, the description is relatively simple, and the relevant part can be referred to the method part.

[0077] The above description of the disclosed embodiments enables a person skilled in the art to implement or use the present application. Various modifications to the embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A flexible variable diameter induction coil device suitable for brazing pipe fittings, characterized in that, It includes: The coil body (1) is provided with an open ring part (11) for heating workpieces, and the two ends of the coil body (1) corresponding to the open ring part (11) extend with pull parts (12), respectively; The two ends of the tensioning rope (2) are respectively connected to the two pull parts (12); The tensioning mechanism (3) acts on the tensioning rope (2) and causes the open ring part (11) to deform through the pull part; The coil clamping assembly (4) acts on the pull part (12) and guides the sliding of the pull part (12); The support (5) provides the installation basis of the tensioning mechanism (3) and the coil clamping assembly (4), and the support (5) is provided with a cooling water channel (51) inside, which is used for cooling the coil clamping assembly (4) and the coil body (1); The power supply frame (6) is provided on the support (5) and is in contact with the pull part (12) for conduction.

2. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, It also includes a orthopedic rod (7) which is placed in the open ring part (11) and limits the deformation aperture of the open ring part (11).

3. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, The coil body (1) is formed by stacking multiple layers of copper sheets, and the corresponding open ring part (11) of the coil body (1) is located on the outside of the support (5).

4. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, The tensioning mechanism (3) includes a winding wheel (31), a screw rod seat (32), a screw rod (33), and a stop block (34), the winding wheel (31) has two groups, the two groups of winding wheels (31) and the screw rod seat (32) are arranged on the side of the support (5) close to the tensioning rope (2), the screw rod (33) is threadedly connected with the screw rod seat (32), the stop block (34) is arranged on one end of the screw rod (33) close to the tensioning rope (2), and the axial displacement of the screw rod (33) causes the stop block (34) to change the pulling state of the tensioning rope (2).

5. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, The coil clamping assembly (4) includes a guide wheel (41), an insulating partition plate (42), and a partition plate seat (43), the guide wheels (41) are arranged in pairs on the side of the support (5) close to the open ring part (11), and the two groups of guide wheels (41) are arranged on the outside of the two pull parts, the insulating partition plate (42) is fixedly connected with the support (5) through the partition plate seat (43), the insulating partition plate (42) is provided with two parallel arranged channel grooves, and the two channel grooves are used for clamping and guiding the two pull parts (12).

6. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, It also includes a water inlet nozzle (52) and a water outlet nozzle (53), the two side walls of the support (5) are provided with water inlets and water outlets corresponding to the two ends of the cooling water channel (51), the water inlet nozzle (52) is detachably connected with the water inlet, and the water outlet nozzle (53) is detachably connected with the water outlet.

7. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, The power supply frame (6) is rotatably connected with a conductive wheel (8), the conductive wheel (8) rolls and presses the pull part (12), the bottom side of the power supply frame (6) is provided with an insulating seat (9), and the insulating seat (9) is fixedly connected with the support (5).

8. A flexible variable diameter induction coil assembly for brazing pipe fittings according to claim 1 wherein, The tensioning rope (2) is formed of carbon fiber material.

9. A method of welding using a flexible variable diameter induction coil suitable for brazing of pipe fittings, using an induction coil apparatus as claimed in any one of claims 1 to 8, characterised in that, The method comprises the following steps: S1: adjusting the diameter of the split ring, using a straightening rod with a diameter matching that of the pipe to be welded to straighten the split ring; S2: surface pretreatment of the pipe welding area, including oil removal, rust removal, and alcohol cleaning; S3: evenly applying solder paste or placing a solder ring at the pipe welding position; S4: clamping the pipe to be welded using external equipment, so that the welding area is located at the center of the split ring and maintains a suitable gap with the inner wall of the split ring; S5: setting the process parameters, conducting induction brazing, and continuing to maintain the flow of the cooling water path until the temperature drops to a safe range.

10. The method of claim 9, wherein the flexible variable diameter induction coil is adapted for brazing of a pipe fitting. The diameter of the straightening rod in step S1 is 0.5-2 mm larger than the diameter of the pipe.

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