A structure of an oil distribution ring based on welding cladding babbitt alloy and a manufacturing method thereof

Abstract

The application discloses a kind of based on welding cladding babbitt alloy's oil distribution ring structure and manufacturing method, it is related to hydraulic oil distribution technology field of marine adjustable pitch propeller device, including detection platform, transmission device is installed in detection platform, detection platform is installed detection frame near transmission device side, transmission belt is installed with flaw detector, infrared size measuring device is installed on transmission device, transmission device middle part is symmetrically provided with oil distribution ring, the multifunctional switching linkage mechanism of the scheme, first platform and second platform are moved by transmission wheel, transmission belt, cooperate with the effect of arc groove and U-shaped pull plate to realize double-station rapid switching, switching time is controlled within 5 seconds.When detection is carried out in a station, other station can complete feeding simultaneously, form the continuous circulation of "feeding-detection-discharging", single cycle time is controlled within 20 seconds, daily output can reach 5760, compared with traditional single-station equipment efficiency improvement 92%, can satisfy batch production demand.

Description

Technical Field

[0001] This invention relates to the field of hydraulic oil distribution technology for marine controllable pitch propeller devices, specifically to an oil distribution ring structure and manufacturing method based on welded Babbitt alloy cladding. Background Technology

[0002] In the field of hydraulic oil distribution technology for marine controllable pitch propeller systems, the distributor ring, as a core component, must withstand the high pressure, high-frequency relative motion of the hydraulic system, and corrosion from the seawater environment for extended periods. Its performance directly determines the operational stability and service life of the controllable pitch propeller system. Currently, the mainstream manufacturing processes for distributor rings in the industry are mainly divided into two categories: one is to use an integrally cast Babbitt alloy structure, where the Babbitt alloy is directly cast onto the surface of a steel substrate to form a functional layer; the other is to use mechanical inlay or spraying processes to attach Babbitt alloy sheets or coatings to the substrate surface to achieve sealing and wear resistance functions.

[0003] However, traditional processes have many shortcomings in practical applications, severely restricting the production efficiency and performance stability of distribution rings. On the one hand, the process is highly complex and costly: the dovetail groove machining requires specialized tools and precision equipment, increasing the difficulty and time required for substrate machining; the cost of tin in the tinning process accounts for more than 35% of the total raw material cost, and the alloy layer thickness of more than 3mm further exacerbates material consumption. On the other hand, the product qualification rate is low and performance is limited: centrifugal casting requires extremely high precision in controlling mold cleanliness, alloy liquid temperature, and centrifugal speed; even slight deviations can easily lead to porosity, inclusions, or even delamination and scrapping of the alloy layer, with the traditional process achieving a qualification rate of only 85%. Furthermore, the combination of dovetail groove fitting and casting makes it difficult to form a stable metallurgical bond; the bonding strength between the alloy layer and the substrate is only 15-20MPa, which is prone to interlayer delamination under long-term hydraulic transmission conditions, affecting the service life of the distribution ring. In addition, the traditional process involves multiple steps such as preheating, casting, and heat preservation, resulting in a long overall manufacturing cycle that cannot meet the timeliness requirements for mass production of marine equipment. Summary of the Invention

[0004] In view of this, the technical problem to be solved by the present invention is to propose an oil distribution ring structure and manufacturing method based on welded Babbitt alloy, so as to solve the problems in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a method for manufacturing an oil distribution ring based on welded Babbitt alloy, comprising:

[0006] S1, Preliminary preparation and basic processing: Raw material preparation and preliminary processing and cleaning of sealing sleeve (52) and cover plate (51). The forging of sealing sleeve (52) and steel pipe cutting are completed by outsourcing. The relevant standards are strictly followed for acceptance and recording. The sealing sleeve (52) and cover plate (51) are machined to ensure the basic dimensions are compatible. The various deep holes and threaded holes of sealing sleeve (52) are pre-processed in a targeted manner to accurately control the hole depth and allowance. Iron filings in the holes are cleaned and burrs are removed to clear obstacles for subsequent processes.

[0007] S2, Welding, stress relief and semi-finishing: Forged material sealing sleeve (52), normalized after forging and retested in batches for filing, and steel pipe fittings are cut at the same time; the sealing sleeve (52) and cover plate (51) are machined according to the design requirements, and then the axial hole, outer thread hole and multi-specification deep hole of the sealing sleeve (52) are machined. Finally, the iron filings in the hole are cleaned and the sharp edges and burrs are removed.

[0008] S3, Flaw Detection, Cladding and Finishing: This stage focuses on quality inspection, Babbitt alloy cladding, and workpiece precision refinement. Welds are subjected to penetrant testing using a flaw detection device according to standards, and only those that pass the test can be transferred. Babbitt alloy welding and cladding are outsourced, with strict control over bonding strength, pretreatment, and material inspection. Precision turning, surface grinding, boring, and threading are carried out sequentially to accurately control the dimensions and accuracy of inner holes, end faces, outer circles, grooves, and threaded holes, while avoiding processing deformation and residual iron filings.

[0009] S4, Final Machining, Coating and Acceptance: Complete the final precision control, anti-corrosion treatment and quality acceptance of the workpiece; machine the inner hole to ensure that the fit clearance between the oil distribution ring and the oil distribution shaft meets the requirements; apply primer and topcoat to specific outer circles according to standards to ensure corrosion protection and appearance; conduct a comprehensive inspection of the workpiece, and after passing the inspection, apply oil and put it into storage to realize the closed loop of the processing process.

[0010] Preferably, S3 specifically includes:

[0011] S3.1, Machining of oil distribution ring substrate (53): Turn carbon steel oil distribution ring substrate (53) to size Φ214±0.1mm to prepare for subsequent surface treatment and cladding;

[0012] S3.2, Surface pretreatment: The processed oil distribution ring substrate (53) is sandblasted to achieve a surface roughness of Ra=12.5μm, thereby enhancing the bonding force between the oil distribution ring substrate (53) and the Babbitt alloy layer;

[0013] S3.3, Preheating: The oil distribution ring substrate (53) is preheated to 200-250℃ by induction heating and kept at that temperature for 25-35 minutes to reduce the thermal stress during cladding;

[0014] S3.4 Welding cladding: TIG welding is used for automatic wire feeding welding cladding, using Babbitt alloy layer (ZSnSb11Cu6) welding wire, with parameters set as current 90A and welding speed 350mm / min to ensure cladding quality;

[0015] S3.5, Interlayer Temperature Control: During the cladding process, the interlayer temperature is strictly controlled to be <150℃ to prevent material performance degradation or defects caused by excessive temperature.

[0016] S3.6 Cooling: After cladding is completed, allow the workpiece to cool naturally to avoid rapid cooling that could generate internal stress.

[0017] S3.7, Finishing: First turn to Ф209.2±0.05mm, then finish grind to the working dimension Ф210+0.05 / 0mm to ensure the accuracy and fit requirements of the oil distribution ring.

[0018] Preferably, the flaw detection device described in S3 includes a detection platform (1), a transmission device (11) is installed in the detection platform (1), a detection frame (12) is installed on the side of the detection platform (1) near the transmission device (11), a flaw detector (13) is installed on the transmission belt (23), an infrared dimension measuring device (14) is installed on the transmission device (11), an oil distribution ring (16) is symmetrically arranged in the middle of the transmission device (11), and a protective door (15) is symmetrically installed on the transmission device (11). The oil distribution ring manufacturing method based on welded cladding Babbitt alloy further includes a multi-functional switching linkage mechanism (2) and a positioning and pushing mechanism (4).

[0019] The multi-functional switching linkage mechanism (2) is installed in the transmission device (11). The multi-functional switching linkage mechanism (2) is used for the rapid switching and positioning of the oil distribution ring (16).

[0020] The positioning and pushing mechanism (4) is located above the transmission device (11). The positioning and pushing mechanism (4) is used to control and limit the loading and unloading of the oil distribution ring (16).

[0021] Preferably, the multi-functional switching linkage mechanism (2) includes an ultraviolet positioning device (21), which is installed on the transmission device (11) directly below the flaw detector (13). A positioning frame (24) is installed on the transmission device (11) below the flaw detector (13). A transmission wheel (22) is symmetrically rotated on one side of the positioning frame (24). A transmission belt (23) is driven on the transmission wheel (22). A first platform (25) is slidably installed on the positioning frame (24) above the transmission belt (23). The middle part of one side of the first platform (25) is fixedly installed on the transmission belt (23). A positioning plate (27) is fixedly installed in the middle of the positioning frame (24). An arc groove (28) is opened on the positioning plate (27). A second platform (26) is provided on the side of the positioning frame (24) near the first platform (25).

[0022] Preferably, the multi-functional switching linkage mechanism (2) further includes an auxiliary component (3), which includes a slide plate (31). The bottom of the slide plate (31) is slidably mounted on the positioning plate (27), and slide rods (33) are symmetrically slidably mounted on the four corners of the slide plate (31). The upper surface of the slide rods (33) is fixedly mounted on the second platform (26).

[0023] Preferably, a return spring (34) is sleeved on the outer surface of the slide bar (33). One end of the return spring (34) is fixedly installed on the slide plate (31), and the other end of the return spring (34) is fixedly installed on the lower surface of the second platform (26). A U-shaped pull plate (32) is fixedly installed in the middle of the lower surface of the second platform (26). The end of the U-shaped pull plate (32) away from the second platform (26) is slidably installed in the arc groove (28). One side of the slide plate (31) is fixedly installed on the transmission belt (23).

[0024] Preferably, the positioning and pushing mechanism (4) includes a drive disk (41), the middle part of which is rotatably installed in the first platform (25) and the second platform (26), and swing arms (42) are symmetrically fixedly installed on the outer surface of the drive disk (41).

[0025] Preferably, an auxiliary plate (43) is rotatably connected to the end of the swing arm (42) away from the drive disk (41), and a positioning clamp (44) is rotatably installed on the end of the auxiliary plate (43) away from the swing arm (42). A protective cover (48) is slidably installed on the lower surface of the positioning clamp (44), and the protective cover (48) is fixedly installed on the upper surface of the first platform (25). An electric telescopic limit plate (47) is installed on one side of the upper surface of the first platform (25), and the electric telescopic limit plate (47) is electrically connected to the ultraviolet positioning device (21). Miniature wheels (46) are rotatably installed at both ends of the positioning clamp (44), and a positioning transmission belt (45) is driven on the outer surface of the miniature wheel (46).

[0026] An oil distribution ring structure based on welded Babbitt alloy is provided. The oil distribution ring 16 includes a cover plate (51), a sealing sleeve (52) and an oil distribution ring base (53). A Babbitt alloy layer (ZSnSb11Cu6) is welded on the oil distribution ring base (53). The cover plate (51) is installed on both sides of the sealing sleeve (52) and the sealing sleeve (52) is installed in the middle of the sealing sleeve (52).

[0027] Preferably, the thickness of the Babbitt alloy layer (ZSnSb11Cu6) is 1.2-2.0 mm, the surface of the oil distribution ring substrate (53) has no mechanical interlocking structure, and the bonding strength between the Babbitt alloy layer and the substrate is ≥55 MPa.

[0028] Compared with the prior art, the oil distribution ring structure and manufacturing method based on welded Babbitt alloy provided by the present invention have the following beneficial effects:

[0029] First, production efficiency has been greatly improved;

[0030] Traditional single-station equipment operates at a slow pace, making it difficult to meet the demands of mass production. This invention utilizes a multi-functional switching and linkage mechanism. Through transmission wheels and belts, it drives the movement of both the first and second platforms. Combined with the action of an arc-shaped groove and a U-shaped pull plate, it achieves rapid switching between the two stations, with a switching time controlled within 5 seconds. While one station is performing inspection, the other station can simultaneously complete material loading, forming a continuous cycle of "loading-inspection-unloading." This significantly improves efficiency compared to traditional single-station equipment, enabling highly efficient response to the time-sensitive requirements of mass production of marine equipment.

[0031] Second, process costs are significantly reduced;

[0032] In traditional oil distribution ring manufacturing processes, the dovetail groove machining requires specialized tools and precision equipment, increasing the difficulty and time required for substrate machining; furthermore, the alloy layer thickness of over 3mm further exacerbates material consumption. This invention employs a welding cladding process, eliminating the need for mechanical interlocking structures on the oil distribution ring substrate surface, thus removing the dovetail groove machining step and reducing the investment in specialized equipment and tools. Simultaneously, the Babbitt alloy layer thickness is only 1.2-2.0mm, far less than the alloy layer thickness in traditional processes, significantly reducing Babbitt alloy material consumption. Moreover, the elimination of the tinning process significantly reduces raw material and processing costs.

[0033] III. Improved product performance and pass rate;

[0034] Traditional centrifugal casting processes require extremely high precision in controlling mold cleanliness, alloy melt temperature, and centrifugal speed. Even slight deviations can easily lead to porosity, inclusions, or even delamination in the alloy layer, resulting in a yield rate of only 85%. Furthermore, the dovetail groove fitting combined with casting makes it difficult to form a stable metallurgical bond, with the bond strength between the alloy layer and the substrate being only 15-20 MPa. Under long-term hydraulic transmission conditions, interlayer delamination is prone to occur. This invention achieves a surface roughness of Ra=12.5μm on the oil distribution ring substrate through sandblasting, enhancing the bond strength between the substrate and the Babbitt alloy layer. Induction heating preheats the substrate to 200-250℃ and maintains this temperature to reduce thermal stress during cladding. Strict control of the interlayer temperature <150℃ prevents material performance degradation. Ultimately, the bond strength between the Babbitt alloy layer and the substrate is ≥55MPa, significantly improving bond stability. Simultaneously, the precise and controllable welding cladding process parameters, combined with multiple quality inspection processes such as penetrant testing, effectively reduce defects such as porosity and inclusions, significantly improving the product yield rate.

[0035] Fourth, the level of automation and intelligence is higher;

[0036] Traditional processes rely heavily on manual operation in loading, unloading, and positioning, which is not only inefficient but also prone to errors due to human factors. The positioning and pushing mechanism of this invention uses a drive disc to move the swing arm and auxiliary plate, centering the oil distribution ring with a positioning clamp. An electrically connected telescopic limit plate and ultraviolet positioning device enable automatic limiting and precise positioning of the oil distribution ring. The positioning transmission clamp quickly completes the unloading operation of the oil distribution ring. Furthermore, the multi-functional switching linkage mechanism works in conjunction with the positioning and pushing mechanism, achieving automated continuous operation of oil distribution ring processing, inspection, and loading / unloading through programmed control. This reduces manual intervention, minimizes human error, and improves the overall automation and intelligence level of the production process.

[0037] V. Equipment functional integration and environmental optimization;

[0038] Traditional testing equipment has limited functionality, and the fumes and dust generated during testing not only affect accuracy but also endanger operator health. The flaw detection device of this invention integrates a transmission device, a flaw detector, and an infrared dimensional measuring device, enabling simultaneous dimensional measurement while performing flaw detection on the oil distribution ring. Furthermore, the infrared dimensional measuring device is installed on the transmission device near the oil distribution ring, and its internal purification device extracts and purifies the fumes and dust generated during testing, reducing the health hazards to operators, improving the production environment, and achieving both functional integration and optimized environmental performance. Attached Figure Description

[0039] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0040] Figure 2 This is an auxiliary schematic diagram of the three-dimensional structure of the present invention;

[0041] Figure 3 This is a schematic diagram of a half-section of the three-dimensional structure of the present invention;

[0042] Figure 4 This is a schematic diagram of the structural connection relationship of the multifunctional switching linkage mechanism of the present invention;

[0043] Figure 5 For the present invention Figure 4 Enlarged view of point A in the middle;

[0044] Figure 6 This is an auxiliary schematic diagram illustrating the structural connection relationship of the multifunctional switching linkage mechanism of the present invention;

[0045] Figure 7 For the present invention Figure 6 Enlarged view at point B in the middle;

[0046] Figure 8 This is a half-section exploded view of the structural connection relationship of the multifunctional switching linkage mechanism of the present invention;

[0047] Figure 9 This is a schematic diagram of the structural connection relationship of the positioning and pushing mechanism of the present invention;

[0048] Figure 10 For the present invention Figure 9 Enlarged view at point C;

[0049] Figure 11 This is a schematic diagram of the connection relationship of the three-dimensional structure of the oil distribution ring of the present invention;

[0050] Figure 12 This is a schematic diagram of the structural connection relationship of the oil distribution ring in its decomposed state according to the present invention;

[0051] Figure 13 This is a schematic diagram of the traditional oil ring processing technology and the processing technology of this solution in this invention.

[0052] In the picture:

[0053] 1. Inspection table; 11. Transmission device; 12. Inspection frame; 13. Flaw detector; 14. Infrared dimensional measuring device; 15. Protective door; 16. Oil distribution ring;

[0054] 2. Multifunctional switching linkage mechanism; 21. Ultraviolet positioning device; 22. Transmission wheel; 23. Transmission belt; 24. Positioning frame; 25. First platform; 26. Second platform; 27. Positioning plate; 28. Arc groove;

[0055] 3. Auxiliary components; 31. Slide plate; 32. U-shaped pull plate; 33. Slide rod; 34. Return spring;

[0056] 4. Positioning and pushing mechanism; 41. Drive disc; 42. Swing arm; 43. Auxiliary plate; 44. Positioning clamp; 45. Positioning transmission belt; 46. Miniature wheel; 47. Electric telescopic limit plate; 48. Protective cover; 51. Cover plate; 52. Sealing sleeve; 53. Oil distribution ring base. Detailed Implementation

[0057] 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.

[0058] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0059] For an example, please refer to... Figures 1 to 13 As shown:

[0060] To address the problems mentioned in the technical solutions, this application provides an oil distribution ring structure and manufacturing method based on welded clad Babbitt alloy, including a testing platform 1, a transmission device 11 installed in the testing platform 1, a testing frame 12 installed on the side of the testing platform 1 near the transmission device 11, a flaw detector 13 installed on the transmission belt 23, an infrared dimension measuring device 14 installed on the transmission device 11, oil distribution rings 16 symmetrically arranged in the middle of the transmission device 11, and protective doors 15 symmetrically installed on the transmission device 11. The oil distribution ring structure and manufacturing method based on welded clad Babbitt alloy also includes a multi-functional switching linkage mechanism 2 and a positioning and pushing mechanism 4.

[0061] The multi-functional switching linkage mechanism 2 is installed in the transmission device 11. The multi-functional switching linkage mechanism 2 is used for the rapid switching and positioning of the oil distribution ring 16.

[0062] The positioning and pushing mechanism 4 is located above the transmission device 11. The positioning and pushing mechanism 4 is used for the loading and unloading control and limiting of the oil distribution ring 16.

[0063] Specifically, such as Figures 4 to 8 As shown, the ultraviolet positioning device 21 is installed on the transmission device 11 near the flaw detector 13 directly below. A positioning frame 24 is installed on the transmission device 11 near the flaw detector 13 below. A transmission wheel 22 is symmetrically rotated on one side of the positioning frame 24. A transmission belt 23 is driven and installed on the transmission wheel 22. A first platform 25 is slidably installed on the positioning frame 24 near the transmission belt 23. The middle part of one side of the first platform 25 is fixedly installed on the transmission belt 23. A positioning plate 27 is fixedly installed in the middle of the positioning frame 24. An arc-shaped groove 28 is opened on the positioning plate 27. A second platform 26 is provided on the side of the positioning frame 24 near the first platform 25.

[0064] The first platform 25 is fixedly mounted on the transmission belt 23 above the transmission wheel 22 by a fixing block, while the slide plate 31 is fixedly mounted on the transmission belt 23 below the transmission wheel 22 by a fixing block. The rotation of the transmission belt 23 can drive the first platform 25 and the slide plate 31 to move closer or further apart.

[0065] The drive motor fixedly mounted in the middle of the drive wheel 22 and the drive motor of the transmission device 11 are controlled by a controller. When the drive motor located in the drive wheel 22 rotates, the first platform 25 and the second platform 26 switch. The transmission device 11 starts to transmit a certain distance through algorithm control. The transmission distance is flexibly designed according to the size of the oil distribution ring 16. When the drive wheel 22 is transmitting, it will first drive the first platform 25 to slide in the positioning frame 24.

[0066] Specifically, such as Figures 6 to 8 As shown, the bottom of the slide plate 31 is slidably mounted on the positioning plate 27. Slide rods 33 are symmetrically slidably mounted at the four corners of the slide plate 31. The upper surface of the slide rods 33 is fixedly mounted on the second platform 26. A return spring 34 is sleeved on the outer surface of the slide rods 33. One end of the return spring 34 is fixedly mounted on the slide plate 31, and the other end of the return spring 34 is fixedly mounted on the lower surface of the second platform 26. A U-shaped pull plate 32 is fixedly mounted in the middle of the lower surface of the second platform 26. The end of the U-shaped pull plate 32 away from the second platform 26 is slidably mounted in the arc groove 28. One side of the slide plate 31 is fixedly mounted on the transmission belt 23.

[0067] Furthermore, since the slide plate 31 slides on the positioning plate 27 and the bottom of the U-shaped pull plate 32 slides in the arc groove 28, when the transmission belt 23 drives the slide plate 31 to slide, the second platform 26 can start to move downward through the mutual connection between the arc groove 28 and the U-shaped pull plate 32. When the first platform 25 and the second platform 26 approach each other, the U-shaped pull plate 32 will pull the second platform 26 downward through the squeezing in the middle of the arc groove 28. At this time, the return spring 34 will start to be compressed, and the second platform 26 will start to pass under the first platform 25. When the second platform 26 has completely passed under the first platform 25, the squeezing of the positioning plate 27 will make the second platform 26 and the first platform 25 keep at the same level again, thus completing the rapid switching of the dual station. Compared with the prior art of feeding by a single component, this solution uses programmed settings to feed the other oil distribution ring 16 while it is being detected.

[0068] Specifically, such as Figure 9 and Figure 10 As shown, a drive disk 41 is rotatably mounted in the first platform 25 and the second platform 26 respectively. A swing arm 42 is symmetrically fixedly mounted on the outer surface of the drive disk 41. An auxiliary plate 43 is rotatably connected to the end of the swing arm 42 away from the drive disk 41. A positioning clamp 44 is rotatably mounted on the end of the auxiliary plate 43 away from the swing arm 42. A protective cover 48 is slidably mounted on the lower surface of the positioning clamp 44. The protective cover 48 is fixedly mounted on the upper surface of the first platform 25. An electric telescopic limit plate 47 is mounted on one side of the upper surface of the first platform 25. The electric telescopic limit plate 47 is electrically connected to the ultraviolet positioning device 21. Miniature wheels 46 are rotatably mounted on both ends of the positioning clamp 44. A positioning transmission belt 45 is drivenly mounted on the outer surface of the miniature wheels 46.

[0069] When the flaw detector 13 is inspecting the oil distribution ring 16, the oil distribution ring 16 has a certain temperature during the inspection process and is prone to generating water vapor with water droplets in the air, which affects its inspection accuracy. In this solution, an infrared dimension measuring device 14 is installed on the side of the transmission device 11 near the oil distribution ring 16. The infrared dimension measuring device 14 can be activated to extract the smoke and dust generated during the inspection. The internal purification device of the infrared dimension measuring device 14 can purify the inhaled water vapor and dust, thereby reducing the harm of personnel inhaling dust during operation.

[0070] Simultaneously, this solution installs positioning and pushing mechanisms 4 on the first platform 25 and the second platform 26 respectively. These mechanisms, activated by a servo drive motor at the bottom of the drive disk 41, can rotate the drive disk 41. Figure 10As shown, the rotation of the drive disc 41 drives the swing arm 42 to drive the auxiliary plate 43 to pull the positioning clamp 44 to move. The positioning clamp 44 can quickly center the oil distribution ring 16. At the same time, since the electric telescopic limit plate 47 is electrically connected to the ultraviolet positioning device 21, when the oil distribution ring 16 slides to the first platform 25 or the second platform 26 through the transmission device 11, the ultraviolet positioning device 21 can detect and quickly control the raising and lowering of the electric telescopic limit plate 47. The initial blocking of the electric telescopic limit plate 47 can complete the limiting of the oil distribution ring 16. At the same time, the positioning and pushing mechanism 4 can quickly center the oil distribution ring 16. Furthermore, when the oil distribution ring 16 completes the detection... During testing, the electric telescopic limit plate 47 can be retracted by the ultraviolet positioning device 21. At this time, the micro motor in the middle of the positioning transmission clamp 45 is started to rotate, which drives the micro wheel 46 to drive the positioning transmission clamp 45 to rotate. Through the transmission of the positioning transmission clamp 45, the tested oil distribution ring 16 can be quickly unloaded. At the same time, the dual-station switching of the multi-functional switching linkage mechanism 2 can realize a dynamic and continuous loading and unloading control. Compared with the existing technology, this solution can not only increase the detection efficiency of the oil distribution ring 16 by linking the multi-functional switching linkage mechanism 2 with the positioning pusher mechanism 4, but also reduce the cumbersome operation in the loading and unloading process of the oil distribution ring 16, and realize the automated control process.

[0071] The oil distribution ring 16 includes a cover plate 51, a sealing sleeve 52, and an oil distribution ring base 53. A Babbitt alloy layer (ZSnSb11Cu6) is welded onto the oil distribution ring base 53. The cover plate 51 is installed on both sides of the sealing sleeve 52, and the sealing sleeve 52 is installed in the middle of the sealing sleeve 52.

[0072] Preferably, the thickness of the Babbitt alloy layer (ZSnSb11Cu6) is 1.2-2.0 mm, the surface of the oil ring substrate 53 has no mechanical interlocking structure, and the bonding strength between the Babbitt alloy layer and the substrate is ≥55 MPa.

[0073] The specific implementation process is as follows:

[0074] Raw material preparation and acceptance;

[0075] The outsourced unit completed the forging of the sealing sleeve (52mm) and the cutting of the steel pipe. The forging material must meet the relevant standards for hydraulic oil distribution components of marine controllable pitch propellers. The steel pipe material must be suitable carbon steel. After the outsourcing is completed, each item will be inspected according to the standards, with a focus on checking the material composition, mechanical properties, and appearance defects. After acceptance, detailed information such as batch and specifications will be recorded. Babbitt metal welding wire (ZSnSb11Cu6) will be prepared. The surface quality of the welding wire will be checked to ensure that it is free of oxidation, oil, and impurities. The diameter of the welding wire must meet the requirements of the automatic wire feeding system for TIG welding.

[0076] Equipment and tool debugging;

[0077] Debug the lathe to ensure stable parameters such as spindle speed and feed rate. Install the appropriate cutting tool and perform a trial cut after tool setting to verify whether the machining accuracy meets the preliminary machining requirements of the sealing sleeve 52, cover plate 51, and oil ring base 53. Check the TIG welding equipment and debug parameters such as welding current and welding speed to ensure smooth operation of the automatic wire feeding system and stable welding arc. Calibrate the flaw detection device, including the transmission device 11, flaw detector 13, and infrared dimensional measuring device 14 on the inspection table 1, to ensure stable operation of the transmission device, that the sensitivity of the flaw detector meets the penetrant testing standard, and that the accuracy error of the infrared dimensional measuring device is within the allowable range. Debug the multi-functional switching linkage mechanism 2, check the transmission accuracy of the transmission wheel 22 and transmission belt 23, test the switching speed between the first platform 25 and the second platform 26, ensuring that the switching time is controlled within 5 seconds, and simultaneously calibrate the ultraviolet positioning device 21 to ensure positioning accuracy.

[0078] Debug the positioning and pushing mechanism 4, check the motion coordination of the drive plate 41, swing arm 42 and positioning clamp 44, test the transmission speed of the positioning transmission belt 45, and ensure that the loading and unloading control and limit of the oil distribution ring 16 can be accurately completed.

[0079] II. Basic Processing Stage;

[0080] The sealing sleeve and cover plate undergo preliminary machining. The accepted sealing sleeve 52 blank is clamped on a lathe and machined according to the design dimensions. First, the outer diameter and end face are rough-machined to remove excess material, then finish-machined to the basic fit dimensions, ensuring the roundness and cylindricity errors of the sealing sleeve 52 meet the requirements. The cover plate 51 blank is then machined, with strict control over its thickness, diameter, and flatness to ensure proper fit with the sealing sleeve 52. Various deep holes and threaded holes are machined according to the design requirements of the sealing sleeve 52. A special deep-hole drill is used to machine the deep holes, precisely controlling the hole depth and diameter allowance. After machining, special tools are used to clean the metal filings inside the holes, and a file is used to remove burrs from the hole openings and surfaces.

[0081] Stress relief and semi-finishing of the sealing sleeve: The forged sealing sleeve 52 undergoes post-forging normalizing treatment. The sealing sleeve 52 is placed in a heating furnace and heated to a specified temperature, determined by the material composition, generally 850-900℃. It is held at this temperature for a period determined by the material thickness, usually 1-2 hours, and then slowly cooled to room temperature in the furnace to eliminate forging internal stress. After normalizing, the sealing sleeve 52 is retested in batches to test its mechanical properties. If the retest is successful, semi-finishing is performed, involving turning the outer diameter and end face of the sealing sleeve 52 again, machining axial holes, external threaded holes, and deep holes of various specifications to further improve dimensional accuracy. After machining, iron filings are cleaned from the holes, and sharp edges and burrs are removed. The cut steel pipe fittings are then machined to the corresponding dimensions according to design requirements, preparing for subsequent assembly.

[0082] III. Key Processing Stages;

[0083] Machining of the oil distribution ring base: Clamp the carbon steel raw material on the lathe, start the machine, and machine the oil distribution ring base 53 according to the process parameters. First, rough turn to a size close to Φ214±0.1mm, leaving a small machining allowance, and then finish turn to a size of Φ214±0.1mm. Monitor the dimensions in real time during the machining process to ensure that the error is within the allowable range. After machining, remove the workpiece and check the outer diameter and surface quality.

[0084] Surface pretreatment: The processed oil distribution ring substrate 53 is placed in a sandblasting machine. A suitable abrasive particle size, such as quartz sand, is selected. The sandblasting pressure is adjusted to approximately 0.5-0.8 MPa, the sandblasting distance to approximately 100-150 mm, and the sandblasting angle to 45°-60°. The outer surface of the oil distribution ring substrate 53 is sandblasted. After treatment, the surface roughness is checked to ensure Ra=12.5μm, thereby enhancing the bonding force between the oil distribution ring substrate 53 and the Babbitt alloy layer. After sandblasting, the residual abrasive dust on the surface of the oil distribution ring substrate 53 is cleaned with compressed air, and then the surface oil is cleaned with a cleaning agent. It is then dried for later use.

[0085] Preheating treatment: Place the pretreated oil distribution ring substrate 53 inside the heating coil of the induction heating equipment, start the induction heating equipment, set the heating temperature to 200-250℃, monitor the temperature of the oil distribution ring substrate 53 in real time through the temperature sensor during the heating process, and hold the temperature for 25-35 minutes after reaching the set temperature to reduce the temperature difference stress during subsequent cladding. After the holding time is completed, maintain the temperature of the oil distribution ring substrate 53 in preparation for welding cladding.

[0086] Welding and cladding: The preheated oil distribution ring substrate 53 is clamped on the welding worktable. The relative position of the TIG welding torch and the oil distribution ring substrate 53 is adjusted to ensure that the welding torch is aligned with the cladding area. The TIG welding equipment is started, the welding current is set to 90A, the welding speed is set to 350mm / min, and the automatic wire feeding system is turned on to feed in Babbitt alloy welding wire ZSnSb11Cu6 for welding and cladding. During the cladding process, a dedicated person monitors the interpass temperature in real time. The temperature near the cladding area of ​​the oil distribution ring substrate 53 is measured using a temperature monitoring instrument to ensure that the interpass temperature is <150℃. If the temperature approaches or exceeds the set value, the cladding is paused and resumed only after the temperature drops to the specified range to prevent material performance degradation or defects due to excessive temperature.

[0087] Cooling treatment: After the welding cladding is completed, turn off the welding equipment and automatic wire feeding system, remove the oil distribution ring substrate 53 with Babbitt alloy layer from the welding workbench, place it on a special cooling platform, and let it cool naturally at room temperature to avoid internal stress caused by rapid cooling. During the cooling process, it is forbidden to perform forced cooling operations on the workpiece, such as watering or blowing air.

[0088] Finishing; after the workpiece has completely cooled, it is clamped on a lathe and precision turned to a dimension of Ф209.2±0.05mm. During the machining process, high-precision measuring tools such as micrometers are used to measure the dimensions in real time to ensure that the error meets the requirements. After precision turning, the workpiece is transferred to a grinding machine for precision grinding to a working dimension of Ф210+0.05 / 0mm. During the precision grinding process, the grinding speed and feed rate are controlled to ensure that the roundness, cylindricity, and surface roughness of the oil ring meet the accuracy requirements. After machining, the workpiece is removed and the surface chips are cleaned.

[0089] Flaw detection: The finished oil distribution ring 16 is placed on the transmission device 11 of the inspection table 1. The protective door 15 is closed, and the transmission device 11 is started to transport the oil distribution ring 16 to the underside of the flaw detector 13. The flaw detector 13 is started to perform penetrant testing on the weld of the oil distribution ring 16. During the inspection, the infrared dimensional measuring device 14 simultaneously detects the dimensions of the oil distribution ring 16. If the flaw detection finds defects in the weld such as cracks, porosity, slag inclusions, etc., the defect location is marked, and rework is carried out. After rework, flaw detection is performed again until the inspection is qualified. If the dimensional inspection does not meet the requirements, it is returned to the finishing stage for reprocessing. The dual-station switching is achieved by using the multi-functional switching linkage mechanism 2. When the oil distribution ring 16 of one station is undergoing flaw detection, the second platform 26 is driven to move through the transmission wheel 22 and transmission belt 23. With the help of the arc groove 28 and U-shaped pull plate 32, the second platform 26 is switched to the loading station. At the same time, the positioning and pushing mechanism 4 is started, and the drive plate 41 drives the swing arm 42 and auxiliary plate 43 to move, so that the positioning clamp 44 centers the new oil distribution ring 16. The electric telescopic limit plate 47 cooperates to limit the movement, and the loading operation is completed, realizing the continuous cycle of "loading-detection-unloading".

[0090] IV. Final Processing and Acceptance Stage;

[0091] Final turning process: The flaw-tested oil distribution ring 16 is clamped on a high-precision turning machine tool, and the inner hole of the oil distribution ring 16 is finally turned. During the machining process, the cutting parameters are strictly controlled to ensure that the fit clearance between the oil distribution ring 16 and the oil distribution shaft meets the design requirements. After the machining is completed, the inner hole size and roundness are checked with an inside dial indicator to ensure that the accuracy meets the standard.

[0092] Coating treatment: The outer circular surface of the oil distribution ring 16 is pretreated by first sanding the surface with sandpaper to remove the oxide scale and impurities, then cleaning the surface oil stains with a cleaning agent, and after drying, applying the primer according to the standard. The thickness of the primer is controlled within the specified range, generally 30-50μm. After the primer dries, the drying time is determined according to the coating requirements, usually 4-6 hours. Then, the topcoat is applied, and the thickness of the topcoat is also controlled within the specified range to ensure that the coating is uniform and free from defects such as sagging and bubbles. After coating, the oil distribution ring 16 is placed in a ventilated and dry environment to allow the coating to fully dry and cure.

[0093] Comprehensive quality inspection;

[0094] Visual inspection: Inspect the coating quality of the oil distribution ring 16 visually, checking for defects such as coating peeling, scratches, and rust. Also check that all components of the oil distribution ring 16 are properly assembled, without looseness or deformation. Dimensional accuracy inspection: Use high-precision measuring tools such as vernier calipers, micrometers, inside dial indicators, and outside dial indicators to comprehensively inspect the key dimensions of the oil distribution ring 16, including the inner hole, outer circle, end face, groove, and screw holes, ensuring that all dimensions meet the design drawing requirements.

[0095] Performance testing: The bonding strength between the Babbitt alloy layer and the oil distribution ring substrate 53 is sampled and tested using a tensile test method to ensure that the bonding strength is ≥55MPa; at the same time, the sealing performance of the oil distribution ring 16 is tested. The hydraulic working environment is simulated, and the sealing condition of the oil distribution ring 16 under the specified pressure is tested. No leakage is considered as qualified.

[0096] Warehousing process: After the oil distribution rings 16 pass inspection, apply anti-rust oil to the surface and then package them. Use moisture-proof and impact-resistant materials such as bubble wrap and cardboard boxes. Label the packaging with product name, specifications, batch number, production date, and other information. Finally, send the packaged oil distribution rings 16 to the warehouse, store them according to batch, and make warehousing records to complete the entire processing procedure.

[0097] Table 1 shows the bonding strength test results for multiple sample surfaces;

[0098]

[0099] Please refer to the above work process. Figures 1 to 13 .

[0100] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0101] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing an oil distribution ring based on welded cladding Babbitt alloy, characterized in that, include: S1, Preliminary preparation and basic processing: Raw material preparation and preliminary processing and cleaning of sealing sleeve (52) and cover plate (51), the forging of sealing sleeve (52) and steel pipe cutting are completed by outsourcing, and the relevant standards are strictly followed for acceptance and recording; the sealing sleeve (52) and cover plate (51) are designed and machined respectively; the deep hole and threaded hole of sealing sleeve (52) are pre-processed in a targeted manner, and the hole depth and allowance are precisely controlled; the iron filings in the hole are cleaned and the burrs are removed; S2, Welding, stress relief and semi-finishing: Forging the sealing sleeve (52), normalizing after forging and retesting and filing in batches, and cutting steel pipe fittings at the same time; turning the sealing sleeve (52) and cover plate (51) respectively according to the design requirements, then machining the axial hole, outer thread hole and multi-specification deep hole of the sealing sleeve (52), and finally cleaning the iron filings in the hole and removing sharp edges and burrs; S3, Flaw Detection, Cladding and Finishing: The weld is subjected to penetrant testing according to the standard using a flaw detection device, and only those that pass the test can be transferred; Babbitt alloy welding and cladding are outsourced; precision turning, surface grinding, boring and threading are carried out in sequence to accurately control the dimensions and accuracy of the inner hole, end face, outer circle, groove and screw hole; The flaw detection device includes a detection platform (1), a transmission device (11) installed in the detection platform (1), a detection frame (12) installed on the side of the detection platform (1) near the transmission device (11), a flaw detector (13) installed on the detection frame (12), an infrared size measuring device (14) installed on the transmission device (11), an oil distribution ring (16) symmetrically arranged in the middle of the transmission device (11), and protective doors (15) symmetrically installed on the transmission device (11). It also includes a multi-functional switching linkage mechanism (2) and a positioning and pushing mechanism (4). The multi-functional switching linkage mechanism (2) is installed in the transmission device (11). The multi-functional switching linkage mechanism (2) is used for the rapid switching and positioning of the oil distribution ring (16). The positioning and pushing mechanism (4) is located above the transmission device (11). The positioning and pushing mechanism (4) is used to control and limit the loading and unloading of the oil distribution ring (16). The multi-functional switching linkage mechanism (2) includes an ultraviolet positioning device (21), which is installed on the transmission device (11) directly below the flaw detector (13). A positioning frame (24) is installed on the transmission device (11) below the flaw detector (13). A transmission wheel (22) is symmetrically rotated on one side of the positioning frame (24). A transmission belt (23) is installed on the transmission wheel (22). A first platform (25) is slidably installed on the positioning frame (24) above the transmission belt (23). The middle part of one side of the first platform (25) is fixedly installed on the transmission belt (23). A positioning plate (27) is fixedly installed in the middle of the positioning frame (24). An arc groove (28) is opened on the positioning plate (27). A second platform (26) is provided on the side of the positioning frame (24) near the first platform (25). The multi-functional switching linkage mechanism (2) also includes an auxiliary component (3), which includes a slide plate (31). The bottom of the slide plate (31) is slidably mounted on the positioning plate (27). Slide rods (33) are symmetrically slidably mounted on the four corners of the slide plate (31). The upper surface of the slide rods (33) is fixedly mounted on the second platform (26). A return spring (34) is sleeved on the outer surface of the slide bar (33). One end of the return spring (34) is fixedly installed on the slide plate (31), and the other end of the return spring (34) is fixedly installed on the lower surface of the second platform (26). A U-shaped pull plate (32) is fixedly installed in the middle of the lower surface of the second platform (26). The end of the U-shaped pull plate (32) away from the second platform (26) is slidably installed in the arc groove (28). One side of the slide plate (31) is fixedly installed on the transmission belt (23). S4, Final Machining, Coating and Acceptance: Complete the final precision control, anti-corrosion treatment and quality acceptance of the workpiece; machine the inner hole to ensure that the fit clearance between the oil distribution ring and the oil distribution shaft meets the requirements; apply primer and topcoat to the outer circle according to the standard to ensure corrosion protection and appearance; conduct a comprehensive inspection of the workpiece, and after passing the inspection, apply oil and put it into storage to realize the closed loop of the processing process.

2. The method for manufacturing an oil distribution ring based on welded Babbitt alloy according to claim 1, characterized in that: S3 specifically includes: S3.1, Machining of oil distribution ring substrate (53): Turn carbon steel oil distribution ring substrate (53) to size Φ214±0.1mm to prepare for subsequent surface treatment and cladding; S3.2, Surface pretreatment: The processed oil distribution ring substrate (53) is sandblasted to achieve a surface roughness of Ra=12.5μm, thereby enhancing the bonding force between the oil distribution ring substrate (53) and the Babbitt alloy layer; S3.3, Preheating: The oil distribution ring substrate (53) is preheated to 200-250℃ by induction heating and kept at that temperature for 25-35 minutes to reduce the thermal stress during cladding; S3.4 Welding cladding: TIG welding with automatic wire feeding is used for welding cladding. Babbitt alloy layer ZSnSb11Cu6 welding wire is used. The parameters are set as follows: current 90A and welding speed 350mm / min to ensure cladding quality. S3.5, Interlayer Temperature Control: During the cladding process, the interlayer temperature is strictly controlled to be <150℃ to prevent material performance degradation or defects caused by excessive temperature. S3.6 Cooling: After cladding is completed, allow the workpiece to cool naturally to avoid rapid cooling that could generate internal stress. S3.7, Finishing: First turn to Ф209.2±0.05mm, then finish grind to the working dimension Ф210+0.05 / 0mm to ensure the accuracy and fit requirements of the oil distribution ring.

3. The method for manufacturing an oil distribution ring based on welded cladding Babbitt alloy according to claim 1, characterized in that: The positioning and pushing mechanism (4) includes a drive disk (41), the middle part of which is rotatably installed in the first platform (25) and the second platform (26), and swing arms (42) are symmetrically fixedly installed on the outer surface of the drive disk (41).

4. The method for manufacturing an oil distribution ring based on welded cladding Babbitt alloy according to claim 3, characterized in that: An auxiliary plate (43) is rotatably connected to one end of the swing arm (42) away from the drive disc (41). A positioning clamp (44) is rotatably installed on one end of the auxiliary plate (43) away from the swing arm (42). A protective cover (48) is slidably installed on the lower surface of the positioning clamp (44). The protective cover (48) is fixedly installed on the upper surface of the first platform (25). An electric telescopic limit plate (47) is installed on one side of the upper surface of the first platform (25). The electric telescopic limit plate (47) is electrically connected to the ultraviolet positioning device (21). Miniature wheels (46) are rotatably installed at both ends of the positioning clamp (44). A positioning transmission belt (45) is installed on the outer surface of the miniature wheel (46).

5. An oil distribution ring structure based on welded clad Babbitt alloy, manufactured by the oil distribution ring manufacturing method based on welded clad Babbitt alloy as described in any one of claims 1-2, characterized in that, The oil distribution ring (16) includes a cover plate (51), a sealing sleeve (52) and an oil distribution ring base (53). The oil distribution ring base (53) is welded with a Babbitt alloy layer ZSnSb11Cu6. The cover plate (51) is installed on both sides of the sealing sleeve (52), and the sealing sleeve (52) is installed in the middle of the sealing sleeve (52).

6. The oil distribution ring structure based on welded clad Babbitt alloy according to claim 5, characterized in that, The thickness of the Babbitt alloy layer ZSnSb11Cu6 is 1.2-2.0 mm, the surface of the oil distribution ring substrate (53) has no mechanical interlocking structure, and the bonding strength between the Babbitt alloy layer and the substrate is ≥55 MPa.

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