Method and device for manufacturing round-arc-edged square-rounding steel coal bucket

Abstract

The application relates to the technical field of steel coal bucket processing, in particular to a manufacturing method and device of a circular-arc-ridge-angle-square-to-round steel coal bucket, which comprises the following steps: cone manufacturing: two U-shaped components are welded through two weld seams, thereby forming a cone; bucket body section manufacturing: four bucket wall plates of a lower bucket body section and an upper bucket body section are respectively assembled and welded; the bucket wall plates are welded, so that the lower bucket body section and the upper bucket body section are shaped; the lower bucket body section and the upper bucket body section are welded; cone-bucket body welding: the cone and the lower bucket body section are assembled in position, and circular seam welding is performed along the joint part, so that the manufacturing of the whole steel coal bucket is completed. The application can reduce the number of weld seams and improve the shaping quality of the cone.

Description

Technical Field

[0001] This application relates to the field of steel coal hopper processing technology, and in particular to a method and apparatus for manufacturing a rounded, angular steel coal hopper. Background Technology

[0002] Steel coal hoppers are essential equipment in industrial production, primarily used for storing and transporting bulk materials such as coal and ore. They are constructed from high-strength steel to withstand long-term heavy loads and wear. In industries such as thermal power generation, metallurgy, and chemicals, steel coal hoppers play a crucial role in ensuring a continuous and stable supply of materials to the production line. Steel coal hoppers are typically manufactured using welding methods.

[0003] Currently, Chinese invention patent application CN118808975A, published on October 22, 2024, proposes a method for processing and assembling a large steel coal hopper with an arc surface, including the following steps: laying out a processing plane using steel plates; marking the first, second, and third layout lines; placing and fixing the fixing bracket and limiting block on the corresponding second and third layout lines; placing the material plate coinciding with the first layout line at the corresponding position on the first layout line, and supporting the fixing bracket on the arc surface of the material plate in the middle and fitting it; spot welding the material plates together before the hopper is formed; and fully welding the material plates together after the hopper is formed to complete the processing and assembly of the hopper.

[0004] The material plate includes several curved panels and several flat panels. Several curved panels form a fan-shaped sidewall, and several flat panels form an isosceles triangular sidewall. The square-shaped funnel is formed by alternating four fan-shaped sidewalls and four isosceles triangular sidewalls. The curved edges of the four fan-shaped sidewalls form the circular opening side of the square-shaped funnel, and the base edges of the four isosceles triangular sidewalls form the square opening side of the square-shaped funnel.

[0005] Regarding the aforementioned technologies, the alternating arrangement of four fan-shaped sidewalls and four isosceles triangular sidewalls creates eight main longitudinal welds. These welds are relatively concentrated, resulting in dense heat input during welding, which can easily lead to excessive local stress in the structure and cause significant welding deformation. Simultaneously, the dense weld distribution increases the difficulty of welding quality control, often resulting in a low pass rate for flaw detection, which may affect the overall structural stability and long-term safety of the steel coal hopper. Summary of the Invention

[0006] This application provides a method and apparatus for manufacturing a square-to-round steel coal hopper with rounded corners, which reduces the number of welds and improves the quality of cone forming.

[0007] A method for manufacturing a steel coal hopper with rounded, curved edges that transitions from square to round, comprising: Cone making: Two U-shaped components are welded together using two weld seams to form a cone; Fighting posture creation: The lower section of the steel coal bucket and the four sides of the upper section of the bucket body are assembled and welded separately. Weld the bucket wall panels to form the lower section of the bucket body and the upper section of the bucket body; Weld the lower section of the bucket body and the upper section of the bucket body together; Conical bucket body welding: The cone is aligned and assembled with the lower section of the bucket body, and circumferential welding is performed along the joint to complete the fabrication of the overall steel coal bucket.

[0008] By adopting the above technical solution, the traditional multi-plate welding method is replaced by the butt joint of two U-shaped components, leaving only two main welds in the cone section, significantly reducing the number of welds and the concentration of welding heat input. This not only effectively alleviates local stress and welding deformation but also reduces the complexity of welding quality control, which is conducive to improving the flaw detection pass rate, thereby enhancing the overall structural stability and long-term operational safety of the steel coal hopper. If the cone is formed by integral cold bending, it faces the challenges of thick steel plates, large springback, and easy buckling.

[0009] Optionally, the U-shaped component is integrally cold-bent and includes an isosceles triangular part, two rounded corner plate parts, and two right-angled triangular parts.

[0010] By adopting the above technical solution, the U-shaped component can be integrally formed in a single cold bending process, thus completely avoiding the joints that may occur with traditional multi-segment welding. This one-piece forming solution not only eliminates the weld seam in this area at its source but also significantly improves the overall structural continuity and mechanical properties of the component. Therefore, the assembly of the entire cone can be completed through only two main weld seams, simplifying the manufacturing process, enhancing the reliability and consistency of the structure, and also helping to reduce welding residual stress and potential defects, thereby improving the product's durability and safety.

[0011] Optionally, the fabrication of the U-shaped component includes: A cone assembly is cut, the cone assembly including a cone plate, a main inner liner plate and two sub-inner liner plates; The main inner lining plate and the sub-inner lining plate are welded to the conical plate, and the main inner lining plate and the sub-inner lining plate form a rounded corner plate deformation area; Several outer pull rings are welded onto the inner liner plate; The U-shaped component is formed by hooking the two ends of several manual hoists with the outer pull rings on both sides. The main inner lining plate and the sub-inner lining plate are welded together.

[0012] By adopting the above technical solution, during the tensile cold bending forming process of the U-shaped component, the deformation zone of the arc corner plate provides the necessary deformation space for the conical assembly, effectively guiding material flow and reducing local stress concentration. Using a manual hoist to pull the outer ring, the hoist is tightened step by step, pausing after each tightening to observe the deformation of the plate surface. This allows the conical plate to slowly bend around the preset bending line until the designed arc angle is achieved. The segmented pulling of the outer ring using a manual hoist enables precise control of the deformation process. Intermittent observation allows for timely adjustment of the pulling force and direction, thereby ensuring forming accuracy and the overall structural stability of the component.

[0013] Optionally, an auxiliary component is used to complete the pulling. The auxiliary component includes several columns, which are welded to the main inner liner plate, so that one end of the manual hoist hooks the outer pull ring and the other end hooks the column.

[0014] By adopting the above technical solution, the column provides a stable and adjustable force point for the pulling process of the manual hoist, which facilitates precise and controllable traction of the components during installation or adjustment, thereby improving the convenience of operation and construction safety.

[0015] Optionally, the auxiliary component further includes a number of spools twice the number of columns and a number of first wire ropes twice the number of columns. The spools are mounted on the columns, one end of the first wire rope is mounted on one end of the manual hoist, the first wire rope is wrapped around the spools, and the other end of the first wire rope is used to connect to the outer pull ring. The other end of the manual hoist is hooked to the lower part of the columns.

[0016] By adopting the above technical solution, when forming U-shaped components, the operator can gradually retract the manual hoist by shaking or pulling its operating chain. During the retraction process, the manual hoist pulls the two first steel wire ropes around their corresponding pulleys and retracts synchronously, thereby applying a uniform and directionally controllable pulling force to the outer pull ring. Under the traction of the first steel wire ropes, the outer pull ring gradually bends the sheet or profile into shape. The entire device has a simple structure, is labor-saving to operate, and the pulling force can be controlled and adjusted via the manual hoist, making it suitable for processing components of different specifications.

[0017] Optionally, the auxiliary component further includes sliders in the same number as the columns, the sliders being slidably mounted on the columns, one end of the first wire rope being connected to the sliders, and the end of the manual hoist away from the columns being hooked onto the sliders.

[0018] By adopting the above technical solution, the manual hoist will drive the slider to move smoothly downward along the column during the retraction process. The downward movement of the slider further pulls the two first steel wire ropes to pass around the corresponding rotating wheels and retract synchronously, thereby applying a uniform and directionally controllable pulling force to the outer pull ring. This causes the two sides of the U-shaped component to move synchronously, ultimately achieving precise and efficient forming of the U-shaped component.

[0019] Optionally, the auxiliary components further include two mounting plates, a rotating shaft, a number of cones equal to the number of columns, and a second steel wire rope twice the number of columns. The mounting plates are welded to the main inner liner plate, the rotating shaft is rotatably mounted on the mounting plate, the cones are rotatably mounted on the rotating shaft, one end of the second steel wire rope is mounted on the cone, and the other end is used to connect to the outer pull ring. One end of the manual hoist is hooked on the cone, and the other end is hooked on the rotating shaft.

[0020] By adopting the above technical solution, during the forming of the U-shaped component, several manual hoists are first used to apply initial traction to the outer pull rings and columns to achieve basic structural shaping. In the final stage of U-shaped component forming, to ensure uniform force and synchronous deformation of all parts, a second steel wire rope is connected, linking it between the outer pull rings and the cone. Subsequently, the rotating shaft is connected to an external power source, and the manual hoists are adjusted appropriately to ensure the second steel wire rope is moderately tensioned. After the power source is started and the rotating shaft rotates, the second steel wire rope is wound to drive all outer pull rings to synchronously move as a whole. To ensure the accuracy of each adjustment and control the gradual closing of the U-shaped component, the outer pull ring furthest from the U-shaped opening is selected as the reference point in each operation. This point has the smallest deformation, facilitating precise monitoring and control of the overall deformation process. After each working cycle of the power source, the remaining manual hoists are immediately adjusted to ensure the second steel wire rope remains taut, thereby maintaining the overall force balance, avoiding local stress concentration, and ultimately achieving precise and stable control of the U-shaped component forming.

[0021] Optionally, after welding the outer pull ring to the inner liner plate, temporary stiffening ribs are welded.

[0022] By adopting the above technical solution, temporary stiffening ribs can be arranged close to the outer tension ring, effectively enhancing the local rigidity and load-bearing capacity of the welded part, thereby stabilizing key stress points during construction and subsequent operations and reducing the risk of deformation or stress concentration.

[0023] Optionally, the cone assembly further includes a plurality of transverse steel pipes and a plurality of longitudinal steel pipes; After the U-shaped component is formed, the two ends of the transverse steel pipe are welded to the sub-inner liner plate, and the longitudinal steel pipe is used so that one end is welded to the sub-inner liner plate and the other end is welded to the main inner liner plate.

[0024] By adopting the above technical solution, after the U-shaped component is bent into place, scissor braces are quickly welded inside the U-shaped component using horizontal and vertical steel pipes to prevent springback. This effectively constrains the deformation of the component, enhances the overall rigidity, and ensures that it maintains the preset shape during subsequent construction and use, thereby improving the reliability and durability of the structure.

[0025] A device for transforming a square steel coal hopper with rounded corners is manufactured using the aforementioned method for manufacturing a square steel coal hopper with rounded corners.

[0026] By optimizing the structural design and forming process, manufacturing efficiency and finished product reliability are significantly improved. The device employs a combination of arcs and angles in the square-to-round transition section, simplifying the traditional multi-segment splicing structure. This not only effectively reduces the number of welds but also lowers the risk of residual stress and deformation caused by welding. During the cone forming process, this design enhances the continuity and consistency of the overall structure, thereby significantly improving the forming quality and geometric accuracy of the cone. Through the application of the above technical solutions, the device ensures structural strength while also considering ease of construction and long-term stability, making it particularly suitable for working environments in industries such as coal and power where high wear resistance, impact resistance, and smooth material conveying are required.

[0027] In summary, this application includes at least one of the following beneficial technical effects: 1. This invention replaces the traditional multi-plate welding with the butt joint of two U-shaped components, leaving only two main welds in the cone section, significantly reducing the number of welds and the concentration of welding heat input. This not only effectively alleviates local stress and welding deformation but also reduces the complexity of welding quality control, which is beneficial for improving the flaw detection pass rate, thereby enhancing the overall structural stability and long-term operational safety of the steel coal hopper. If the cone is formed by integral cold bending, it faces the challenges of thick steel plates, large springback, and easy buckling.

[0028] 2. In the tensile cold bending process of the U-shaped component of this invention, the deformation zone of the arc corner plate provides the necessary deformation space for the conical assembly, effectively guiding material flow and reducing local stress concentration. The inner lining plate avoids constraining the deformation of the steel plate during cold bending.

[0029] 3. After the U-shaped component of the present invention is bent into place, scissor braces are quickly welded inside the U-shaped component using transverse and longitudinal steel pipes to prevent springback, thereby effectively constraining the deformation of the component, enhancing the overall rigidity, and ensuring that it maintains the preset shape during subsequent construction and use, thus improving the reliability and durability of the structure. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the manufacturing method according to an embodiment of this application; Figure 2This is a schematic diagram of the three-dimensional structure of the steel coal hopper according to an embodiment of this application; Figure 3 This is a schematic diagram of the U-shaped component being pulled according to an embodiment of this application. Figure 1 ; Figure 4 This is a schematic diagram showing the positions of the conical plate and the conical reinforcing ribs in an embodiment of this application; Figure 5 This is a schematic diagram of the U-shaped component being pulled according to an embodiment of this application. Figure 2 ; Figure 6 This is a partial three-dimensional structural diagram of the cone assembly according to an embodiment of this application; Figure 7 This is a schematic diagram of the U-shaped component being pulled according to an embodiment of this application. Figure 3 .

[0031] Figure label: 100. Cone; 110. U-shaped component; 111. Isosceles triangle section; 112. Rounded corner plate section; 113. Right triangle section; 120. Conical reinforcing rib; 200. Lower section of bucket body; 210. Lower bucket wall panel; 220. Lower reinforcing rib; 300. Upper part of bucket body; 310. Upper bucket wall panel; 320. Cover plate; 330. Pipe; 340. Upper reinforcing rib; 400. Conical assembly; 410. Conical plate; 420. Main inner lining plate; 430. Sub-inner lining plate; 440. Rounded corner plate deformation zone; 450. Transverse steel pipe; 460. Longitudinal steel pipe; 500, outer pull ring; 600. Manual hoist; 700. Auxiliary components; 710. Column; 711. Column hanging ring; 712. Column body; 713. Column base plate; 720. Slider; 730. Rotating wheel; 740. First steel wire rope; 750. Mounting plate; 760. Rotating shaft; 770. Conical cylinder; 771. First hanging ring of conical cylinder; 772. Second hanging ring of conical cylinder; 773. Connecting plate; 780. Second steel wire rope; 790. Guide rail; 800. Temporary stiffening ribs. Detailed Implementation

[0032] The following combination Figures 1 to 7 This application will be described in further detail.

[0033] refer to Figure 2 This embodiment provides a device for transforming a square steel coal hopper with rounded corners into a round shape. Its overall structure includes: a hopper upper section 300, a hopper lower section 200, and a cone 100. The hopper upper section 300, the hopper lower section 200, and the cone 100 are connected in sequence to ensure a continuous and stable supply of materials to the production line.

[0034] refer to Figure 2 The upper section 300 of the bucket body includes four upper bucket wall panels 310, a cover plate 320, a number of pipes 330 and a number of upper reinforcing ribs 340. The four upper bucket wall panels 310 are connected in sequence. The cover plate 320 is installed on the upper end of the four upper bucket wall panels 310. The pipes 330 are installed on the cover plate 320. The upper reinforcing ribs 340 are installed on the outside of the upper bucket wall panels 310.

[0035] The pipeline 330 includes a coal chuting channel and a dust removal ventilation duct, etc.

[0036] refer to Figure 2 The lower section 200 of the bucket body includes four lower bucket wall panels 210 and several lower reinforcing ribs 220. The four lower bucket wall panels 210 are connected in sequence, and the lower reinforcing ribs 220 are installed on the outside of the lower bucket wall panels 210. The lower end of the upper bucket wall panel 310 is installed on the upper end of the lower bucket wall panel 210.

[0037] refer to Figure 3 and 4 The cone 100 includes two U-shaped components 110 and several cone reinforcing ribs 120. The two U-shaped components 110 are connected to each other, and the cone reinforcing ribs 120 are installed on the outside of the U-shaped components 110. The upper end of the U-shaped components 110 is installed on the lower end of the lower bucket wall plate 210.

[0038] refer to Figure 5 The U-shaped component 110 includes an isosceles triangular portion 111, two rounded corner plates 112, and two right-angled triangular portions 113. One side of the rounded corner plate 112 is connected to the isosceles triangular portion 111, and the other side is connected to the right-angled triangular portion 113. The right-angled triangular portion 113 on one U-shaped component 110 is connected to the right-angled triangular portion 113 on another U-shaped component 110.

[0039] refer to Figure 1 This embodiment provides a method for manufacturing a square-to-round steel coal hopper with rounded corners, including: S1: Cone construction: S11: Fabrication of U-shaped component 110.

[0040] S111: Cutting cone assembly 400, reference Figure 6 The cone assembly 400 includes a cone plate 410, a main inner liner plate 420, two sub-inner liner plates 430, a number of transverse steel pipes 450 and a number of longitudinal steel pipes 460.

[0041] S112: Weld the cone assembly 400, and weld the main inner liner plate 420 and the sub-inner liner plate 430 to the cone plate 410. The main inner liner plate 420 and the sub-inner liner plate 430 form an arc corner plate deformation area 440.

[0042] During the tensile cold bending process of the U-shaped component 110, the arc corner plate deformation zone 440 provides the necessary deformation space for the cone component 400, effectively guiding material flow and reducing local stress concentration.

[0043] S113: Weld the outer conical reinforcing rib 120, leaving a 200mm gap in the area corresponding to the arc corner plate portion 112, and then weld it after bending.

[0044] S114: Weld several outer pull rings 500 onto the inner lining plate 430; pull the outer pull rings 500 on both sides, tightening them by 50mm each time and then pausing to observe the deformation of the plate surface until the edge displacement reaches the designed arc length; thus forming the U-shaped component 110.

[0045] refer to Figure 3 After welding the outer pull ring 500 onto the inner lining plate 430, a temporary stiffening rib 800 is welded on. The temporary stiffening rib 800 can be arranged close to the outer pull ring 500 to effectively enhance the local rigidity and load-bearing capacity of the welded part, thereby stabilizing key stress points during construction and subsequent operations and reducing the risk of deformation or stress concentration.

[0046] The segmented pulling of the outer pull ring 500 causes the conical plate 410 to slowly bend around a preset bending line until the designed arc angle is reached. This achieves precise control over the deformation process, allowing for timely adjustment of the pulling force and direction through intermittent observation, thereby ensuring forming accuracy and overall structural stability of the component.

[0047] The U-shaped component 110 is integrally cold-bent, comprising an isosceles triangular portion 111, two rounded corner plates 112, and two right-angled triangular portions 113. The U-shaped component 110 can be integrally formed in a single cold-bending process, thus completely avoiding the seams that may occur with traditional multi-segment welding. This integral forming solution not only eliminates weld seams in this area at the source but also significantly improves the overall structural continuity and mechanical properties of the component.

[0048] S115: After the U-shaped component 110 is formed, the two ends of the transverse steel pipe 450 are respectively welded to the inner lining plate 430, and the longitudinal steel pipe 460 is used so that one end is welded to the inner lining plate 430 and the other end is welded to the main inner lining plate 420.

[0049] The transverse steel pipe 450 and the longitudinal steel pipe 460 use φ48 steel pipe.

[0050] After the U-shaped component 110 is bent into place, scissor braces are quickly welded inside the U-shaped component 110 using transverse steel pipes 450 and longitudinal steel pipes 460 to prevent springback, thereby effectively restraining the deformation of the component, enhancing the overall rigidity, and ensuring that it maintains the preset shape during subsequent construction and use, thus improving the reliability and durability of the structure.

[0051] S116: Weld the main inner lining plate 420 and the sub-inner lining plate 430.

[0052] S12: Two U-shaped components are butt-welded at 110 joints.

[0053] Two U-shaped components 110 are welded together by two weld seams to form a cone 100.

[0054] The entire cone 100 can be assembled through only two main welds, which simplifies the manufacturing process, enhances the reliability and consistency of the structure, and helps reduce residual welding stress and potential defects, thereby improving the product's durability and safety.

[0055] S13: Welded reinforcement ribs.

[0056] Weld the reinforcing ribs in the area corresponding to the arc corner plate 112.

[0057] S2: Fighting Body Formation: S21: Construction of wall panels.

[0058] The four bucket wall panels of the lower section 200 and the upper section 300 of the bucket body are assembled and welded separately; after the bucket wall panels are completed, reinforcing ribs are welded to their outer sides.

[0059] S22: Welding of bucket wall panels.

[0060] The bucket wall panels are welded to form the lower section 200 and the upper section 300 of the bucket body.

[0061] S23: Welded cover plate 320 and several pipes 330.

[0062] S24: Weld the lower section 200 of the bucket body and the upper section 300 of the bucket body.

[0063] S3: Conical bucket body welding: The cone 100 is aligned and assembled with the lower section 200 of the bucket body, and circumferential welding is performed along the joint to complete the fabrication of the overall steel coal bucket.

[0064] The traditional method of welding multiple plates together has been replaced by butt welding of two U-shaped components at 110mm, leaving only two main welds in the conical section. This significantly reduces the number of welds and the concentration of welding heat input. This not only effectively alleviates localized stress and welding deformation but also reduces the complexity of welding quality control, improving the pass rate of flaw detection and thus enhancing the overall structural stability and long-term operational safety of the steel coal hopper.

[0065] refer to Figure 3 In S114, when pulling the outer pull rings 500 on both sides, the auxiliary component 700 is used to complete the pulling, including the following methods: Example 1: Reference Figure 5 The auxiliary component 700 includes a plurality of columns 710.

[0066] The column 710 includes two column hanging rings 711 and a column body 712. The two column hanging rings 711 are symmetrically welded to the column body 712. The column body 712 is welded to the main inner liner plate 420, so that one end of the manual hoist 600 hooks the outer pull ring 500 and the other end hooks the column hanging ring 711.

[0067] The column body 712 provides a stable and adjustable force point for the pulling process of the manual hoist 600, which facilitates precise and controllable traction of components during installation or adjustment, thereby improving the convenience of operation and construction safety.

[0068] After the traction is completed, remove column 710.

[0069] Example 2: Reference Figure 5The auxiliary component 700 includes a plurality of columns 710, two mounting plates 750, a rotating shaft 760, a number of cones 770 equal to the number of columns 710, a number of first cone rings 771 equal to the number of columns 710, a number of second cone rings 772 equal to the number of columns 710, a number of connecting plates 773 equal to the number of columns 710, and a number of second steel wire ropes 780 equal to the number of columns 710. Each column 710 includes two column rings 711 and a column body 712. The two column rings 711 are symmetrically welded to the column body 712, and the column body 712 is welded to the main inner lining plate 420. The mounting plates 750 are welded to the main inner lining plate 420. On the main inner liner plate 420, the rotating shaft 760 is bearing connected to the mounting plate 750, the cone cylinder 770 is bearing connected to the rotating shaft 760, the first hanging ring 771 of the cone cylinder is installed on the cone cylinder 770, two first hanging rings 771 of the cone cylinder on each cone cylinder 770 are symmetrically arranged, the second hanging ring 772 of the cone cylinder is installed on the cone cylinder 770, the connecting plate 773 is installed on the rotating shaft 760, one end of the second wire rope 780 is connected to the first hanging ring 771 of the cone cylinder, and the other end is used to connect to the outer pull ring 500, one end of the manual hoist 600 is hooked on the second hanging ring 772 of the cone cylinder, and the other end is hooked on the connecting plate 773.

[0070] The cones 770 have the same taper, and when the U-shaped component 110 is finally formed, the included angle formed by the two right-angled triangular portions 113 is the same.

[0071] refer to Figure 5During the forming of the U-shaped component 110, several manual hoists 600 are used to apply initial traction to the outer pull rings 500 and the columns 710 to achieve basic structural shaping. In the final stage of forming the U-shaped component 110, to ensure uniform stress and synchronous deformation of all parts, a second steel wire rope 780 is connected, linking it between the outer pull rings 500 and the first hanging ring 771 of the cone. Subsequently, the rotating shaft 760 is connected to an external power source, and the manual hoists 600 are adjusted appropriately. The manual hoists 600 drive the second hanging ring 772 of the cone to move, which in turn drives the cone 770 to rotate, thus placing the second steel wire rope 780 in a moderately tensioned state. After the power source is started and the rotating shaft 760 rotates, the second steel wire rope 780 is wound around to drive all the outer pull rings 500 to move synchronously as a whole. To ensure the accuracy of each adjustment and control the gradual closing of the U-shaped component 110, the outer pull ring 500, which is furthest from the U-shaped opening, is selected as the reference point in each operation. This point has the smallest deformation, making it easy to accurately monitor and control the overall deformation process. After each work cycle is completed, the remaining manual hoists 600 must be adjusted immediately to ensure that the second wire rope 780 remains taut, thereby maintaining the overall force balance, avoiding local stress concentration, and ultimately achieving precise and stable control of the U-shaped component 110 forming.

[0072] After the tensioning is completed, remove column 710 and mounting plate 750.

[0073] Example 3: Reference Figure 7 The auxiliary component 700 includes a plurality of columns 710, twice the number of rotating wheels 730, twice the number of first steel wire ropes 740, the same number of sliders 720 as the columns 710, and the same number of guide rails 790 as the columns 710; each column 710 includes a column body 712 and a column base plate 713, the column base plate 713 being welded to the bottom of the column body 712, and the column body 712 being welded to the main inner lining plate 420. The rotating wheel 730 is mounted on the column 710, the guide rail 790 is mounted at the center of the column body 712 in the width direction, the slider 720 is slidably mounted on the guide rail 790, one end of the first wire rope 740 is connected to the slider 720 and surrounds the rotating wheel 730, and the other end is used to connect to the outer pull ring 500. One end of the manual hoist 600 is hooked on the slider 720, and the other end of the manual hoist 600 is hooked on the column base plate 713.

[0074] During the stretch forming of the U-shaped component 110, the operator can gradually retract the manual hoist 600 by shaking or pulling its operating chain. During this retraction, the manual hoist 600 drives the slider 720 to move smoothly downwards along the guide rail 790. The downward movement of the slider 720 further pulls the two first steel wire ropes 740 around their corresponding rotating wheels 730 and simultaneously retracts them, thus applying a uniform and directionally controllable pulling force to the outer pull ring 500. This causes the two sides of the U-shaped component 110 to move synchronously, ultimately achieving precise and efficient forming of the U-shaped component 110. The entire device has a simple structure, is easy to operate, and the pulling force can be controlled and adjusted via the manual hoist 600, making it suitable for processing components of different specifications.

[0075] After the traction is completed, remove column 710.

[0076] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for manufacturing a steel coal hopper with rounded, curved edges that transitions from square to round, characterized in that, include: Cone making: Two U-shaped components (110) are welded together by two weld seams to form a cone (100). Fighting posture creation: The lower section (200) and the upper section (300) of the steel coal bucket body are assembled and welded separately. The bucket wall panels are welded to form the lower section (200) and the upper section (300) of the bucket body; Weld the lower section (200) and the upper section (300) of the bucket body; Conical bucket body welding: The cone (100) is aligned and assembled with the lower section (200) of the bucket body, and circumferential welding is performed along the joint to complete the fabrication of the overall steel coal bucket.

2. The method for manufacturing a square-to-round steel coal hopper with rounded edges according to claim 1, characterized in that: The U-shaped component (110) is integrally cold-bent and includes an isosceles triangular part (111), two rounded corner plate parts (112) and two right-angled triangular parts (113).

3. The method for manufacturing a rounded, square-to-round steel coal hopper according to claim 2, characterized in that: The fabrication of the U-shaped component (110) includes: A cutting cone assembly (400) is provided, the cone assembly (400) including a cone plate (410), a main inner liner (420) and two sub-inner liners (430). The main inner lining plate (420) and the sub-inner lining plate (430) are welded to the conical plate (410), and the main inner lining plate (420) and the sub-inner lining plate (430) form a rounded corner plate deformation area (440). Several outer pull rings (500) are welded onto the inner liner plate (430); The U-shaped component (110) is formed by hooking the two ends of several manual hoists (600) with the outer pull rings (500) on both sides. The main inner liner plate (420) and the sub-inner liner plate (430) are welded together.

4. The method for manufacturing a rounded-corner steel coal hopper according to claim 3, characterized in that: The pulling is accomplished using an auxiliary component (700), which includes several columns (710). The columns (710) are welded to the main inner liner plate (420), so that one end of the manual hoist (600) hooks onto the outer pull ring (500), and the other end hooks onto the column (710).

5. The method for manufacturing a rounded-corner steel coal hopper according to claim 4, characterized in that: The auxiliary component (700) also includes twice the number of pulleys (730) and twice the number of first wire ropes (740) of the columns (710). The pulleys (730) are mounted on the columns (710). One end of the first wire rope (740) is mounted on one end of the manual hoist (600). The first wire rope (740) surrounds the pulleys (730). The other end of the first wire rope (740) is used to connect to the outer pull ring (500). The other end of the manual hoist (600) is hooked on the lower part of the column (710).

6. The method for manufacturing a rounded, square-to-round steel coal hopper according to claim 5, characterized in that: The auxiliary component (700) also includes the same number of sliders (720) as the column (710), the sliders (720) are slidably disposed on the column (710), one end of the first wire rope (740) is connected to the slider (720), and the end of the manual hoist (600) away from the column (710) is hooked on the slider (720).

7. The method for manufacturing a square-to-round steel coal hopper with rounded edges according to claim 5, characterized in that: The auxiliary component (700) also includes two mounting plates (750), a rotating shaft (760), a number of cones (770) equal to the number of columns (710), and a second steel wire rope (780) twice the number of columns (710). The mounting plates (750) are welded to the main inner liner plate (420). The rotating shaft (760) is rotatably mounted on the mounting plates (750). The cones (770) are rotatably mounted on the rotating shaft (760). One end of the second steel wire rope (780) is mounted on the cone (770), and the other end is used to connect to the outer pull ring (500). One end of the manual hoist (600) is hooked on the cone (770), and the other end is hooked on the rotating shaft (760).

8. The method for manufacturing a rounded-corner steel coal hopper according to any one of claims 3-7, characterized in that: After welding the outer pull ring (500) onto the inner liner plate (430), a temporary stiffening rib (800) is welded.

9. The method for manufacturing a rounded-corner steel coal hopper according to any one of claims 3-7, characterized in that: The conical assembly (400) also includes a number of transverse steel pipes (450) and a number of longitudinal steel pipes (460). After the U-shaped component (110) is formed, the two ends of the transverse steel pipe (450) are welded to the sub-inner liner plate (430) respectively, and the longitudinal steel pipe (460) is used so that one end is welded to the sub-inner liner plate (430) and the other end is welded to the main inner liner plate (420).

10. A device for converting square-to-round steel coal hoppers with rounded edges, characterized in that: It is manufactured using the method described in any one of claims 1-9 for producing a rounded steel coal hopper with rounded corners.

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