A device and process for repairing wear-resistant roller surface by overlay welding

Abstract

This invention discloses a wear-resistant roller surface overlay repair device and its process, relating to the field of overlay repair technology. It includes a track located inside a moving component, a follow-up air exchange mechanism located in a second air duct, and a stroke-triggered air exchange mechanism located on the inner wall of the second air duct and above the track. This invention cleverly utilizes the alternating staggered distribution of arc and planar sections in the track, allowing two sets of welding heads to weld alternately, ensuring that the area welded first avoids the direct heat impact of subsequent welding heads and prevents softening from repeated heating. It also cleverly utilizes the feature of the moving pipe moving synchronously with the welding head and positioned behind it, allowing the first and second air ducts to alternately output air through a set of fans. Furthermore, this invention cleverly utilizes first and second adjusting plates with different curvatures set at different stages. When the control plates in the first and second air ducts move to different stages, the first and second adjusting plates push the force plate, causing the control plate to rotate and open different air volumes.

Description

Technical Field

[0001] This invention relates to the field of welding repair technology, specifically to a welding repair device and process for the surface of wear-resistant rollers. Background Technology

[0002] The wear-resistant roller surface overlay repair device and its process are automated welding equipment specifically designed to repair various industrial wear roller surfaces. Its core function is to "re-wear" a layer of high-hardness wear-resistant alloy onto the worn roller, restoring its dimensions and significantly extending its service life.

[0003] When repairing wear-resistant rollers by overlay welding, a fixed cooling method is generally adopted. The existing equipment fixes the cooling nozzle to the side of the welding head, sets a constant gas flow rate and pressure, and continuously blows air at the same angle and intensity throughout the process. After the operator selects a set of welding and cooling parameters based on experience, continuous overlay welding is started, so that the welding head moves at a constant speed along the roller surface until it covers the entire roller surface.

[0004] However, using a fixed single cooling method and continuous welding process can easily lead to uneven hardness distribution along the welding direction: the areas welded first and later cool slower and have lower hardness, while the middle area cools relatively faster and has higher hardness, forming a wavy distribution. At the same time, the areas welded first are easily softened by repeated heating from the heat of the later welds, and there is cumulative damage in the heat-affected zone, which may produce microcracks or grain coarsening. In addition, the differences in heat accumulation at different welding stages cannot be controlled in a targeted manner, and the cooling effect is difficult to match the actual heat dissipation or protection requirements throughout the process.

[0005] To address the aforementioned issues, there is an urgent need for innovative designs based on the existing wear-resistant roller surface overlay repair device and its processes. Summary of the Invention

[0006] The present invention addresses the problem of overly simplistic solutions in existing technologies by providing a significantly different solution. Specifically, the present invention aims to provide a wear-resistant roller surface overlay repair device and its process to solve the problems mentioned in the background art, such as wavy hardness distribution, softening of the pre-welded area, and cumulative damage in the heat-affected zone caused by the difference in continuous welding heat accumulation under a single cooling method.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a wear-resistant roller surface overlay repair device, comprising a device body, movable components installed on both sides of the device body, and a welding head movably disposed above the movable components, and further comprising: The track is located inside the moving component and consists of two parts: an arc segment and a planar segment. The arc segment and the planar segment are symmetrically and evenly distributed. The follow-up air exchange mechanism is installed in the second air duct; Simultaneously, a stroke-triggered air exchange mechanism is installed on the inner wall of the second air duct and above the track; The follow-up ventilation mechanism includes a first air duct and a second air duct that are movably disposed above the moving component. The inner walls of the first air duct and the second air duct are respectively movably inserted with moving pipes. One end of the second air duct is provided with a connecting section. The outer wall of the connecting section is fixedly sleeved with an auxiliary pipe. The bottom end of the auxiliary pipe is connected to a conveying pipe. The movable pipe is fixed to the welding head; The first air duct and the second air duct are connected by a delivery pipe; The stroke-triggered ventilation mechanism includes a first adjusting plate and a second adjusting plate fixed to the top of the track. Control plates are rotatably installed in the first and second air ducts respectively, and a force-bearing plate is fixedly sleeved on the top of the control plate. The width and curvature of the first and second adjusting plates are different; As the welding head moves in the track, it alternates between arc-shaped and planar sections to ensure uniform weld layer hardness and stable structure. Simultaneously, the welding head drives the moving pipe to alternately shift and switch air ducts to cool the processing area. The air volume is adjusted by controlling the rotation of the control plate using the first and second staged adjustment plates.

[0008] Preferably, movable components are symmetrically arranged on both sides of the main body of the device, and a movable plate is movably arranged at the top of the movable components; The main body of the device is provided with chuck assemblies at both ends, and a moving component is provided at the bottom end of one set of chuck assemblies.

[0009] Preferably, the moving component drives the moving plate and the welding head to move laterally, the welding head is movably inserted into one side of the moving plate, and a corresponding sliding groove is provided on the moving plate; The top of the movable plate is fixed with a first air duct and a second air duct, which are staggered and symmetrically distributed. The bottom end of the welding head is movably inserted into the track.

[0010] Preferably, the first air duct consists of a short conical section, a cylindrical section, and a long conical section. The bottom end of the short conical section of the force-bearing plate is connected to a conveying pipe, and the cylindrical section and the long conical section are respectively adapted to the moving pipe.

[0011] Preferably, the first adjusting plate is fixed to the top of the track, and a second adjusting plate is fixed to one side of the first adjusting plate; The first and second adjusting plates are arranged radially symmetrically, and the conveying pipe and the second adjusting plates divide the workpiece into different stages evenly.

[0012] Preferably, the length of the track is adapted to the stroke of the welding head, the track is composed of alternating equally spaced arc segments and planar segments, and the track is fixed inside the moving component; The tracks are symmetrically and alternately distributed horizontally.

[0013] Preferably, the control plate is adapted to the inner wall diameter of the second air duct, the surface of the control plate is provided with a sealing ring, and the two ends of the control plate passing through the second air duct are provided with sealing rings; A fan is installed at one end of the second air duct. The second air duct consists of three parts: a short conical section, a cylindrical section, and a long conical section. The connection between the second air duct and the fan is the short conical section, and the section located at the control panel in the second air duct is the cylindrical section with the same diameter. The section in the second air duct where the movable pipe is inserted is a long conical section. The first and second air ducts are respectively movably connected to the movable pipe, and the first and second air ducts are provided with matching sliding grooves. The cylindrical section and the long conical section are connected by a connecting section with the same overall diameter. The moving pipe consists of two parts: an annular section and a conical section. The diameter of the annular section of the moving pipe is adapted to the inner wall of the connecting section, and the diameter of the conical section of the moving pipe is adapted to the long conical section of the second air duct.

[0014] Preferably, the surface of the connecting section is provided with an annular groove, and the inner wall of the auxiliary tube is provided with a cavity, the cavity being positioned corresponding to the annular groove; The bottom end of the connecting section is connected to a conveying pipe, and the top end of the conveying pipe located below the first air duct is provided with a jet nozzle.

[0015] Preferably, the connection between the second adjusting plate and the first adjusting plate, as well as one end of the second adjusting plate, are chamfered, and the width of the second adjusting plate is smaller than the width of the first adjusting plate. The second adjusting plate and the first adjusting plate are in contact with the force-bearing plate, and both ends of the force-bearing plate are chamfered. The bottom end of the force-bearing plate and the top end of the second air duct are both fixed with torsion springs, and the torsion springs are wrapped around the surface of the control plate.

[0016] A process for repairing the surface of a wear-resistant roller by overlay welding includes the following steps: S1: Two sets of staggered and symmetrical second air ducts and welding heads are driven to move at a constant speed by moving components. The welding heads and the track are initially staggered. While the welding heads move laterally, they move back and forth in the arc section and plane section of the track. The welding heads maintain a constant distance from the workpiece in the plane section for welding repair. When entering the arc section, the distance between the welding heads and the workpiece increases, forming an empty stroke. The two sets of welding heads work alternately. S2: A moving pipe that moves back and forth synchronously with the welding head in the first and second air ducts. When the welding head moves forward (planar section), it drives the moving pipe forward in the second air duct, exposing the connecting section so that the airflow is diverted through the delivery pipe to the first air duct for heat dissipation. When the welding head moves backward (arc section), the moving pipe moves backward in the second air duct and seals the connecting section. The airflow returns to its original concentration, and the second air duct discharges air. The first and second air ducts alternately blow air to cool the workpiece when the welding head is not working on this side. S3: A rotatable control plate is provided at the inlet of the second air duct. The first and second adjustment plates correspond to the three stages of workpiece repair at different processing stages (initial, intermediate, and final). In the initial stage, the control plate is sealed. In the intermediate stage, the second adjustment plate pushes the force plate and control plate to be rotated open at a small angle. In the final stage, the second adjustment plate pushes the force plate and control plate to be rotated open at a large angle, matching the heat dissipation and protection requirements of different stages.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention cleverly utilizes the alternating staggered distribution of arc-shaped and planar sections in the track, allowing two sets of welding heads to work alternately. This prevents the area to be welded first from being directly affected by the heat of the subsequent welding head, avoiding repeated heating and softening. The arc-shaped section's lifting stroke naturally creates intermittent cooling, while the planar section is welded normally. This eliminates the difference in cooling rate between the first and subsequent welding areas, suppresses the wavy distribution of hardness, reduces accumulated damage and microcracks in the heat-affected zone, and improves the uniformity of the weld overlay and its resistance to spalling.

[0018] 2. This invention cleverly utilizes the feature that the moving pipe moves synchronously with the welding head and is behind it. The first and second air ducts are controlled by a set of fans to alternately output air, so that the second air duct dynamically switches between sealed connection and gap diversion. When the connection section is in the planar section, the moving pipe moves forward to expose the connection section and form a gap, and the airflow is diverted to the first air duct for output. When it enters the arc section, the moving pipe resets the seal, restores concentrated strong cooling, and distributes cooling airflow as needed. It provides dispersed slow cooling for the high heat input area of ​​the planar section and concentrated rapid cooling for the low heat input area of ​​the arc section, matching the cooling rate of each position, avoiding hardness peaks and valleys caused by slow cooling rate in the first welded area and fast cooling rate in the middle area, and suppressing grain coarsening in the heat-affected zone.

[0019] 3. This invention cleverly utilizes first and second adjustment plates with different curvatures set at different stages. When the control plates in the first and second air ducts move to different stages, the first and second adjustment plates push the force plate to rotate and open different air volumes, so that the initial, middle and tail stages obtain equally adjustable air intensity, compensating for the changes in the workpiece's own heat accumulation: weak cooling in the initial stage prevents cracking, strong cooling in the middle stage suppresses the hardness peak, and moderate cooling in the tail stage avoids softening. Thus, the difference in structure caused by uneven cooling rate is eliminated in different areas, and a continuous and stable transition of the hardness and microstructure of the entire roller surface is achieved. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the first three-dimensional structure of the present invention.

[0021] Figure 2 This is a schematic diagram of the second three-dimensional structure of the present invention.

[0022] Figure 3 This is a schematic diagram of the third three-dimensional structure of the present invention.

[0023] Figure 4 This is a three-dimensional structural diagram of the first and second air ducts of the present invention.

[0024] Figure 5 This is a three-dimensional cross-sectional structural diagram of the track and moving plate of the present invention.

[0025] Figure 6 This is a three-dimensional structural diagram of the second air duct and welding head of the present invention.

[0026] Figure 7 This is a three-dimensional cross-sectional structural diagram of the second air duct of the present invention.

[0027] Figure 8 This is a three-dimensional structural diagram of the control board and the load-bearing plate of the present invention.

[0028] Figure 9 This is a three-dimensional cross-sectional structural diagram of the connecting segment and the ring of the present invention.

[0029] Figure 10 This is a three-dimensional structural diagram of the first air duct of the present invention.

[0030] Figure 11 This is a three-dimensional structural diagram of the first and second adjusting plates of the present invention.

[0031] Figure 12 This is a schematic diagram showing the usage status of the second air duct and the moving pipe of the present invention.

[0032] Figure 13 This is a schematic diagram showing the usage state of the control board and the force plate of the present invention.

[0033] In the diagram: 1. Main body of the device; 2. Moving component; 3. Welding head; 4. First air duct; 5. First adjusting plate; 6. Track; 7. Moving plate; 8. Second air duct; 9. Connecting section; 10. Fan; 11. Auxiliary pipe; 12. Moving pipeline; 13. Control plate; 14. Force plate; 15. Conveying pipe; 16. Second adjusting plate. Detailed Implementation

[0034] 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, those skilled in the art who have not made any innovative embodiments are all within the scope of protection of the present invention.

[0035] Please see Figures 1 to 13 The present invention provides a technical solution: a wear-resistant roller surface overlay repair device, comprising a device body 1, movable components 2 installed on both sides of the device body 1, and a welding head 3 movably disposed above the movable components 2, and further comprising: The track 6 is located inside the moving component 2. The track 6 consists of two parts: an arc segment and a plane segment. The arc segment and the plane segment of the track 6 are symmetrically and evenly distributed. The follow-up air exchange mechanism is installed in the second air duct 8; Simultaneously, a stroke-triggered air exchange mechanism is installed on the inner wall of the second air duct 8 and above the track 6; The follow-up ventilation mechanism includes a first air duct 4 and a second air duct 8 movably disposed above the moving component 2. The inner walls of the first air duct 4 and the second air duct 8 are respectively movably inserted with moving pipes 12. One end of the second air duct 8 is provided with a connecting section 9. The outer wall of the connecting section 9 is fixedly sleeved with an auxiliary pipe 11. The bottom end of the auxiliary pipe 11 is connected to a conveying pipe 15. The movable pipe 12 is fixed to the welding head 3; The first air duct 4 and the second air duct 8 are connected by the delivery pipe 15; The stroke-triggered ventilation mechanism includes a first adjusting plate 5 and a second adjusting plate 16 fixed to the top of the track 6. A control plate 13 is rotatably provided in the first air duct 4 and the second air duct 8 respectively. A force-bearing plate 14 is fixedly sleeved on the top of the control plate 13. The width and curvature of the first adjusting plate 5 and the second adjusting plate 16 are different; When the moving plate 7 moves in the track 6, the weld layer hardness is uniform and the structure is stable by alternating arc-shaped and planar sections. The welding head 3 drives the moving pipe 12 to alternate displacement and switch the air duct to cool the processing area. The control plate 13 is rotated to adjust the air volume by using the staged first adjustment plate 5 and second adjustment plate 16.

[0036] In specific implementation, movable components 2 are symmetrically arranged on both sides of the main body 1 of the device, and a movable plate 7 is movably arranged at the top of the movable components 2. The main body 1 of the device is provided with chuck assemblies at both ends, and a moving component 2 is provided at the bottom of one set of chuck assemblies.

[0037] Additionally, it should be noted that the chuck assembly is used to clamp the workpiece and drive it to rotate at a constant speed, providing the circumferential feed required for welding. The moving assembly 2 drives the moving plate 7 and the welding head 3 to move laterally along the workpiece axis, realizing the alternating movement of the welding head 3 between the planar section and the arc section of the track 6. Another set of ball screws located at the bottom of one set of chucks can independently drive the chuck to make fine adjustments along the axis, which helps to compensate for workpiece clamping errors and workpiece loading and unloading.

[0038] In specific implementation, the moving component 2 drives the moving plate 7 and the welding head 3 to move laterally. The welding head 3 is movably inserted on one side of the moving plate 7, and a corresponding sliding groove is opened on the moving plate 7. The top of the moving plate 7 is fixed with the first air duct 4 and the second air duct 8, which are staggered and symmetrically distributed. The bottom end of the welding head 3 is movably inserted in the track 6.

[0039] Additionally, it should be noted that the moving component 2 drives the moving plate 7 to move, and the moving plate 7 simultaneously causes the welding head 3 to move laterally. However, the welding head 3 slides in both the planar and arc sections of the track 6. When it is in the planar section, the welding head 3 is flush with the moving plate 7 and performs welding repair on the workpiece. When it is in the arc section, the welding head 3 moves backward, increasing the distance between it and the workpiece to create an idle stroke. At this time, the welding head 3 moves forward on one side of the moving plate 7 and above the moving component 2.

[0040] In specific implementation, the first air duct 4 consists of a short conical section, a cylindrical section and a long conical section. The bottom end of the short conical section of the load-bearing plate 14 is connected to the conveying pipe 15, and the cylindrical section and the long conical section are respectively adapted to the moving pipe 12.

[0041] Additionally, it should be noted that the first air duct 4 and the second air duct 8 are alternately arranged on the side of the welding head 3, located behind the workpiece processing. They are centrally controlled by a set of fans 10 to adapt to the different working stages of the two sets of welding heads 3. When the two sets of welding heads 3 are working at the same time, one set is located in the arc section and the other in the flat section to repair the workpiece. When the workpiece is not being welded in the arc section, the workpiece is cooled in the processing area, which reduces ineffective diffusion airflow, reduces air volume consumption and waste, saves costs in the long run, and also reduces the temperature of the area where the welding has just been completed, reduces heat accumulation, reduces coarsening of the heat-affected zone or the formation of cracks, helps to blow away welding slag, spatter and oxide scale, provides a clean base surface for subsequent welds, facilitates uniform heat dissipation, reduces warping or residual stress caused by local overheating of the workpiece, shortens the natural cooling waiting time, and allows the repair process to proceed continuously.

[0042] In practice, the first adjusting plate 5 is fixed at the top of the track 6, and the second adjusting plate 16 is fixed on one side of the first adjusting plate 5; the first adjusting plate 5 and the second adjusting plate 16 are arranged radially symmetrically, and the conveying pipe 15 and the second adjusting plate 16 divide the workpiece into different stages evenly.

[0043] Additionally, it should be noted that the process is divided into three stages: initial, intermediate, and final, based on the material of the workpiece and the processing time. The control plate 13 opens to different degrees in different stages, changing the effective cross-sectional area of ​​the first air duct 4 and the second air duct 8. The air outlet cross-sectional area can be dynamically adjusted according to the heat accumulation of the workpiece. In the initial stage, the workpiece temperature is low, so the control plate 13 is closed, and there is no airflow to prevent rapid cooling and cracking. In the intermediate stage, the heat input is high, and the force plate 14 contacts and rotates with the second adjustment plate 16, causing the control plate 13 to rotate slightly and open. The airflow is moderate, balancing cooling and protection. In the final stage, rapid cooling is required to shorten the process cycle. The force plate 14 contacts and rotates with the first adjustment plate 5, causing the control plate 13 to open significantly, increasing the airflow.

[0044] In practice, the length of track 6 is adapted to the stroke of welding head 3. Track 6 is composed of alternating arc segments and planar segments with equal spacing. Track 6 is fixed inside the moving component 2. The horizontal planes of track 6 are alternately and symmetrically distributed.

[0045] Additionally, it should be noted that track 6 divides the welding path into alternating arc segments and planar segments. The forward and backward movement of welding head 3 is forced by the geometry of track 6. Furthermore, the distance between track 6 and the workpiece is greater in the arc segment than in the planar segment. The distance between the arc segment and the planar segment is adapted to the processing distance between welding head 3 and the workpiece. When welding head 3 is far from the workpiece in the arc segment, it is used for empty welding.

[0046] Planar section: Welding head 3 performs overlay welding, while the corresponding first air duct 4 and second air duct 8 do not produce air; forming a large-area protective air curtain to prevent weld oxidation, while uniform heat dissipation avoids local overheating; Arc section: Welding head 3 is far away from the non-welding area, and concentrated airflow can quickly cool the adjacent area that has just completed overlay welding, reducing the accumulation of heat-affected zone. This on-demand switching avoids insufficient protection or overcooling caused by a single airflow mode, improving the hardness and bonding strength of the overlay layer; it does not rely on sensors, solenoid valves or complex electrical controls, avoiding the risk of electronic component failure in high-temperature environments, while reducing the workload of program debugging and troubleshooting.

[0047] In specific implementation, the control plate 13 is adapted to the inner wall diameter of the second air duct 8, the surface of the control plate 13 is provided with a sealing ring, and the two ends of the control plate 13 that pass through the second air duct 8 are provided with sealing rings. In addition, it should be noted that the sealing ring reduces air leakage, enabling the first air duct 4 and the second air duct 8 to cool the workpiece with a preset air volume, thereby improving the accuracy and uniformity of cooling.

[0048] A fan 10 is installed at one end of the second air duct 8. The second air duct 8 consists of three parts: a short conical section, a cylindrical section, and a long conical section. The connection between the second air duct 8 and the fan 10 is the short conical section. The cylindrical section with the same diameter is located at the control panel 13 in the second air duct 8. The long conical section is where the movable pipe 12 is inserted in the second air duct 8. The first air duct 4 and the second air duct 8 are respectively movably connected to the movable pipe 12, and the first air duct 4 and the second air duct 8 are provided with matching sliding grooves. The cylindrical section and the long conical section are connected by a connecting section 9. The connecting section 9 has the same overall diameter. The movable pipe 12 consists of two parts: an annular section and a conical section. The diameter of the annular section of the movable pipe 12 is matched with the diameter of the inner wall of the connecting section 9, and the diameter of the conical section of the movable pipe 12 is matched with the long conical section of the second air duct 8.

[0049] In addition, it should be noted that the force plate 14 and the welding head 3 are rigidly linked. The forward or backward movement of the welding head 3 immediately changes the sealing and diversion state of the first air duct 4 and the second air duct 8, so that the welding mode and the air supply mode are strictly synchronized. There is no lag or false triggering of the electrical control. Each processing area can obtain the most timely air volume matching. When it is located in the arc section, the annular section of the moving pipe 12 is located in the moving plate 7. The diameters of the two are matched, and the air volume is output completely.

[0050] In specific implementation, the connection between the second adjusting plate 16 and the first adjusting plate 5, as well as one end of the second adjusting plate 16, are chamfered. The width of the second adjusting plate 16 is smaller than the width of the first adjusting plate 5. The second adjusting plate 16 and the first adjusting plate 5 are in contact with the force plate 14, and both ends of the force plate 14 are chamfered. The bottom end of the force plate 14 and the top end of the second air duct 8 are both fixed with torsion springs, and the torsion springs are wrapped around the surface of the control plate 13.

[0051] Additionally, it should be noted that the chamfer setting ensures smooth contact between the force plate 14 and the first adjusting plate 5 and the second adjusting plate 16. As the force plate 14 moves laterally under the drive of the second air duct 8, it can move laterally smoothly and rotate accurately and in a timely manner, controlling different air volume at different working stages.

[0052] In specific implementation, the surface of the connecting section 9 is provided with an annular groove, the inner wall of the auxiliary pipe 11 is provided with a cavity, and the cavity corresponds to the position of the annular groove; the bottom end of the connecting section 9 is connected to the conveying pipe 15, and the top end of the conveying pipe 15 located below the first air duct 4 is provided with a jet nozzle.

[0053] Additionally, it should be noted that when the connecting section 9 is exposed, air flows out from the annular groove of the connecting section 9 and flows along the conveying pipe 15 into the first air duct 4. The welding head 3 at the first air duct 4 processes the rear end area of ​​the welding head 3 at the second air duct 8. The air volume at the first air duct 4 is slightly weaker than that at the second air duct 8, which can avoid excessive cooling of the cooled area, reduce heat stress concentration and waste of protective gas, ensure rapid solidification of the high-temperature weld to prevent hot cracking, and prevent uneven shrinkage of the cooled area due to rapid cooling, thereby improving the quality of the weld overlay and the dimensional stability of the workpiece.

[0054] The jet nozzle sprays concentrated airflow in the form of a high-speed, small-section jet, which can transport airflow from the second air duct 8 to the first air duct 4 to maintain sufficient airflow. At the same time, the jet entrains surrounding air, enhances the convective heat transfer effect, quickly reduces the temperature of the roller surface that has just completed welding, and effectively blows away welding slag and dust in the far-end area, thereby making up for the problem of airflow attenuation at the far end and ensuring that the entire arc section and even the end of the workpiece obtain uniform and efficient cooling and cleaning effect.

[0055] A process for repairing the surface of a wear-resistant roller by overlay welding includes the following steps: S1: Two sets of staggered and symmetrical second air ducts 8 and welding heads 3 are driven to move at a constant speed by moving components 2. The initial positions of welding heads 3 and track 6 are staggered. While the welding heads 3 move laterally, they move back and forth in the arc section and plane section of track 6. The welding heads 3 maintain a constant distance from the workpiece for welding repair in the plane section. When entering the arc section, the distance between the welding heads 3 and the workpiece increases to form an empty stroke. The two sets of welding heads 3 work alternately. S2: The moving pipe 12 in the first air duct 4 and the second air duct 8 moves back and forth synchronously with the welding head 3. When the welding head 3 moves forward (planar section), it drives the moving pipe 12 to move forward in the second air duct 8, exposing the connecting section 9 so that the airflow is diverted through the delivery pipe 15 to the first air duct 4 for heat dissipation. When the welding head 3 moves backward (arc section), the moving pipe 12 moves backward in the second air duct 8 and seals the connecting section 9. The airflow returns to its original concentration, and the second air duct 8 discharges air. The first air duct 4 and the second air duct 8 alternately blow air to cool the workpiece when the welding head 3 is not working on this side. S3: A rotatable control plate 13 is provided at the inlet of the second air duct 8. The first adjustment plate 5 and the second adjustment plate 16 correspond to the three stages of workpiece repair at different processing stages (initial, intermediate, and final). In the initial stage, the control plate 13 is sealed. In the intermediate stage, the second adjustment plate 16 pushes the force plate 14 and the control plate 13 to be rotated open by a small angle. In the final stage, the second adjustment plate 16 pushes the force plate 14 and the control plate 13 to be rotated open by a large angle, matching the heat dissipation and protection requirements of different stages.

[0056] Working principle: When using this wear-resistant roller surface overlay welding repair device and its process, the workpiece is first clamped and fixed by the chuck assembly, and driven to rotate at a uniform speed. The moving assembly 2 drives the moving plate 7 and the welding head 3 to move at a uniform speed in the lateral direction. Two sets of symmetrically arranged... The track 6, the moving plate 7, and the welding head 3 are initially staggered, so that the welding head 3 can alternately maintain a constant distance from the workpiece, thereby caulking the wear-resistant alloy onto the surface of the workpiece.

[0057] When the moving component 2 is in operation, the connecting section 9 performs continuous welding. The welding head 3 on one side of the second air duct 8 contacts the workpiece first. The track 6 is composed of alternating planar and arc-shaped sections. When the welding head 3 on the side of the second air duct 8 is located in the planar section, the welding head 3 moves laterally under the drive of the moving plate 7, and slides laterally on one side of the moving plate 7 in the track 6 according to the planar and arc-shaped sections to repair the workpiece by welding. At the same time, the welding head 3 on the side of the first air duct 4 is located in the arc-shaped section and is far away from the workpiece's travel empty stroke. This segmented staggered processing realizes the time and space separation of welding and cooling, effectively avoids heat accumulation and improves repair efficiency and surface quality.

[0058] When the welding head is in the initial stage of the workpiece, fan 10 is not working, and there is no airflow in the first air duct 4 and the second air duct 8. After the repair enters the intermediate stage, when the welding head 3 is working in the planar section, such as Figure 12 As shown, the forward movement of the welding head 3 directly drives the moving pipe 12 to move radially along the second air duct 8. The moving pipe 12 slides forward (i.e. the forward direction of the welding head 3) to expose the connecting section 9. The air volume from the main air duct second air duct 8 is diverted to the auxiliary air duct first air duct 4 through the annular groove of the connecting section 9 and the conveying pipe 15, so as to achieve wide-range dispersed air outlet to meet the welding protection and heat dissipation requirements of the planar section.

[0059] Similarly, when one set of welding heads 3 is working on the arc section, the welding head 3 moves backward, causing the moving pipe 12 to reset, such as... Figure 7 As shown, the connecting section 9 is resealed and covered, and the air volume in the main air duct second air duct 8 can no longer be diverted to the auxiliary air duct first air duct 4. All the air volume is concentrated and sprayed out from the end of the second air duct 8. In the arc section, the air outlet of the first air duct 4 or the second air duct 8 on the side of the welding head 3 quickly cools the processed area, removes welding slag spatter, reduces thermal deformation, and improves repair efficiency.

[0060] During the welding process, the workpiece will sequentially go through different stages (initial, intermediate, and final). In the initial stage, the control board 13 is sealed within the first air duct 4 and the second air duct 8. In the intermediate stage, such as... Figure 13As shown, the force plate 14 contacts the second adjustment plate 16 and is pushed by it to drive the control plate 13 to rotate. The control plate 13 opens slightly in the second air duct 8. At the tail end, the force plate 14 contacts the first adjustment plate 5 and is pushed by it to open significantly, thereby changing the effective cross-sectional area of ​​the air outlet and increasing the air volume, so that each section can obtain a precisely matched cooling air volume and realize zoned air control.

[0061] Throughout the entire overlay repair process, the moving component 2 drives the welding head 3 to continuously travel along the alternating planar and arc-shaped sections of the track 6. Each time the welding head 3 passes through a planar section, it advances to complete one overlay repair. Each time it passes through an arc-shaped section, it automatically retracts to form an empty stroke. At the same time, the first air duct 4 and the second air duct 8 emit air according to the working status of the welding head 3: air is emitted to cool the workpiece when it is in the arc-shaped section, and no air is emitted when the welding head 3 is working in the planar section. The control board 13 switches the air volume in real time according to the workpiece stage. This cycle repeats until all planar sections of the entire roller surface are evenly overlaid and covered, completing the surface repair of the wear-resistant roller.

[0062] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 device for repairing the surface of a wear-resistant roller by overlay welding, comprising a main body (1), movable components (2) installed on both sides of the main body (1), and a welding head (3) movably disposed above the movable components (2), characterized in that, Also includes: The track (6) is located inside the moving component (2). The track (6) consists of two parts: an arc segment and a planar segment. The arc segment and the planar segment of the track (6) are symmetrically and evenly distributed. The follow-up air exchange mechanism is installed in the second air duct (8); Simultaneously, a stroke-triggered ventilation mechanism is installed on the inner wall of the second air duct (8) and above the track (6); The following air exchange mechanism includes a first air duct (4) and a second air duct (8) movably disposed above the moving component (2). The inner walls of the first air duct (4) and the second air duct (8) are respectively movably inserted with moving pipes (12). One end of the second air duct (8) is provided with a connecting section (9). The outer wall of the connecting section (9) is fixedly sleeved with an auxiliary pipe (11). The bottom end of the auxiliary pipe (11) is connected to a conveying pipe (15). The movable pipe (12) is fixed to the welding head (3); The first air duct (4) and the second air duct (8) are connected by a delivery pipe (15); The stroke-triggered ventilation mechanism includes a first adjusting plate (5) and a second adjusting plate (16) fixed to the top of the track (6). A control plate (13) is rotatably provided in the first air duct (4) and the second air duct (8). A force-bearing plate (14) is fixedly sleeved on the top of the control plate (13). The width and curvature of the first adjusting plate (5) and the second adjusting plate (16) are different; When the welding head (3) moves in the track (6), it alternates between arc-shaped and planar sections to make the weld layer hardness uniform and the structure stable. The welding head (3) synchronously drives the moving pipe (12) to alternately shift and switch the air duct to cool the processing area. The first adjustment plate (5) and the second adjustment plate (16) are used to control the rotation of the control plate (13) to adjust the air volume.

2. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The main body (1) of the device is symmetrically provided with movable components (2) on both sides, and a movable plate (7) is movably provided at the top of the movable components (2). The device body (1) is provided with chuck assemblies at both ends, and a moving component (2) is provided at the bottom end of one set of chuck assemblies.

3. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The moving component (2) drives the moving plate (7) and the welding head (3) to move laterally. The welding head (3) is movably inserted on one side of the moving plate (7), and a corresponding sliding groove is provided on the moving plate (7). The top of the movable plate (7) is fixed with a first air duct (4) and a second air duct (8), and the first air duct (4) and the second air duct (8) are staggered and symmetrically distributed. The bottom end of the welding head (3) is movably inserted into the track (6).

4. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The first air duct (4) consists of a short conical section, a cylindrical section and a long conical section. The bottom end of the short conical section of the force plate (14) is connected to a conveying pipe (15). The cylindrical section and the long conical section are respectively adapted to the moving pipe (12).

5. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The first adjusting plate (5) is fixed to the top of the track (6), and a second adjusting plate (16) is fixed to one side of the first adjusting plate (5). The first adjusting plate (5) and the second adjusting plate (16) are arranged radially symmetrically, and the conveying pipe (15) and the second adjusting plate (16) divide the workpiece into different stages evenly.

6. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The length of the track (6) is adapted to the stroke of the welding head (3). The track (6) is composed of alternating arc segments and planar segments at equal intervals. The track (6) is fixed inside the moving component (2). The horizontal planes of the orbits (6) are symmetrically alternated.

7. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The control plate (13) is adapted to the inner wall diameter of the second air duct (8), and the surface of the control plate (13) is provided with a sealing ring. The two ends of the control plate (13) that pass through the second air duct (8) are provided with sealing rings. A fan (10) is installed at one end of the second air duct (8). The second air duct (8) consists of three parts: a short conical section, a cylindrical section and a long conical section. The connection between the second air duct (8) and the fan (10) is a short conical section. The section located at the control panel (13) in the second air duct (8) is a cylindrical section with the same diameter. The second air duct (8) has a long conical section where the movable pipe (12) is inserted. The first air duct (4) and the second air duct (8) are respectively movably connected to the movable pipe (12), and the first air duct (4) and the second air duct (8) are provided with matching sliding grooves. The cylindrical section and the long conical section are connected by a connecting section (9). The connecting section (9) has the same overall diameter. The moving pipe (12) consists of two parts: a circular section and a conical section. The diameter of the circular section of the moving pipe (12) is adapted to the inner wall of the connecting section (9). The conical section of the moving pipe (12) is adapted to the long conical section of the second air duct (8).

8. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The surface of the connecting section (9) is provided with an annular groove, and the inner wall of the auxiliary tube (11) is provided with a cavity, the cavity being positioned corresponding to the annular groove; The bottom end of the connecting section (9) is connected to the conveying pipe (15), and the top end of the conveying pipe (15) located below the first air duct (4) is provided with a jet nozzle.

9. The wear-resistant roller surface overlay repair device according to claim 1, characterized in that: The connection between the second adjusting plate (16) and the first adjusting plate (5) and one end of the second adjusting plate (16) are chamfered, and the width of the second adjusting plate (16) is smaller than the width of the first adjusting plate (5). The second adjusting plate (16) and the first adjusting plate (5) are in contact with the force plate (14) respectively, and both ends of the force plate (14) are chamfered; The bottom end of the force plate (14) and the top end of the second air duct (8) are both fixed with torsion springs, and the torsion springs are wrapped around the surface of the control plate (13).

10. A process for repairing the surface of a wear-resistant roller by overlay welding, applicable to the wear-resistant roller surface overlay welding repair device according to any one of claims 1-9, characterized in that, The repair process includes the following steps: S1: The two sets of staggered and symmetrical second air ducts (8) and welding heads (3) are driven to move at a constant speed through the moving component (2). The initial positions of the welding head (3) and the track (6) are staggered. While the welding head (3) moves laterally, it moves back and forth in the arc section and plane section of the track (6). The welding head (3) maintains a constant distance from the workpiece in the plane section for welding repair. When it enters the arc section, the distance between the welding head (3) and the workpiece increases to form an empty stroke. The two sets of welding heads (3) work alternately. S2: The moving pipe (12) in the first air duct (4) and the second air duct (8) moves back and forth synchronously with the welding head (3). When the welding head (3) moves forward (planar section), it drives the moving pipe (12) to move forward in the second air duct (8), exposing the connecting section (9) so that the airflow is diverted through the delivery pipe (15) to the first air duct (4) for heat dissipation. When the welding head (3) moves backward (arc section), the moving pipe (12) moves backward in the second air duct (8) and seals the connecting section (9). The airflow returns to its original concentration, and the second air duct (8) discharges air. The first air duct (4) and the second air duct (8) alternately weld the welding head on this side. (3) When not working, blow air to cool the workpiece; S3: The second air duct (8) is equipped with a rotatable control plate (13) at the inlet. The first adjustment plate (5) and the second adjustment plate (16) correspond to the three stages of workpiece repair at different processing stages (initial, intermediate, and tail). In the initial stage, the control plate (13) is sealed. In the intermediate stage, the second adjustment plate (16) pushes the force plate (14) and the control plate (13) to be rotated open at a small angle. In the tail stage, the second adjustment plate (16) pushes the force plate (14) and the control plate (13) to be rotated open at a large angle, matching the heat dissipation and protection requirements of different stages.

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