Zirconia ceramic rod positioner
The zirconia ceramic rod locator addresses the issues of high costs and low quality in curved steel box bridge welding by providing precise gap control and stable adhesion, achieving high welding success rates and safety improvements.
Patent Information
- Application Number
- CN202422312964.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-23
- Publication Date
- 2025-07-15
- Estimated Expiration
- 2034-09-23
AI Technical Summary
During the welding process, existing ceramic liners have problems such as high cost, slipping of the molten pool metal, falling off of the viscose and uneven gaps, resulting in low welding qualification rate, especially in the welds of curved steel box bridges.
Zirconia ceramic rod locator is used, including U-shaped connecting rods, fixing cards and permanent magnet rods, to determine the weld gap and fix the pad plate by spot welding, which is suitable for welding of curved steel box bridges.
It reduces welding costs, improves welding qualification rate, reduces rework rate and safety risks, adapts to the uneven gap of the curved structure, and achieves efficient single-sided double-sided forming.
Smart Images
Figure CN223098209U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of steel structure welding processes, in particular to a zirconia ceramic rod positioner. Background Art
[0002] The main welds between the webs and the top plates, and between the webs and the bottom plates of curved steel box girders are usually full penetration fillet welds. After welding, non-destructive testing is required to determine the weld quality. If defects are detected, the welds need to be gouged and reworked, resulting in losses in multiple aspects such as welding consumables, welding energy, labor, and construction period. Since the working conditions are poor during welding inside the box and there are significant safety risks in welding in a large enclosed space, a single-sided welding and double-sided forming welding process is mostly used at present. The main welds of curved steel box girders have an irregular curve shape, and it is difficult to make the welding gaps between the top plates and the webs, and between the bottom plates and the webs completely standard and consistent, further resulting in difficulty in stabilizing the welding qualification rate at a high level.
[0003] Taking the solution of patent CN114346383A, named "A submerged arc welding single-sided welding and double-sided forming process" as an example, this patent discloses process steps such as pretreatment, grooving, and welding of the welds of the pipe base material. Among them, the overall solution of this patent is a conventional welding process, which mainly has the following defects: 1. The welding cost is significantly increased due to the ceramic backing itself; 2. The ceramic backing has no adhesion to the cladding metal, and the cladding metal in the molten pool is easy to slide off, especially obvious in welding positions such as horizontal welding, vertical welding, and overhead welding; 3. The ceramic backing is attached to the surface of the base material by adhesive. When welding, the adhesive of the ceramic backing itself is easy to fall off. Especially in the flat welding position, under the action of the gravity of the molten pool after heating, the backing is more likely to fall off, which has an adverse effect on the welding process. 4. The ceramic backing has certain requirements for the size of the weld gap of the base material assembly. The uneven gap has a greater impact on the welding qualification rate, and welding cannot be carried out for larger gaps. Summary of the Utility Model
[0004] The technical problem to be solved by the utility model is to provide a zirconia ceramic rod positioner suitable for welding welds with larger gaps.
[0005] The technical solution adopted by the utility model to solve its technical problems is: a zirconia ceramic rod positioner, including a backing positioning device. The backing positioning device includes a connecting rod. The shape of the connecting rod is U-shaped. Fixed clamps are provided at both ends of the connecting rod. The fixed clamps are perpendicular to the ends of the connecting rod. Anytime zirconia ceramic rod is provided at the bottom of the fixed clamp, and a permanent magnet rod is provided at the top of the fixed clamp. The zirconia ceramic rod and the permanent magnet rod are parallel to the ends of the connecting rod. The diameter of the zirconia ceramic rod is equal to the size of the gap between the bottom of the backing plate and the bottom plate. The distance between the centers of the two fixed clamps is less than the length of the backing plate. A handle is provided at the bending part of the middle section of the U-shaped connecting rod.
[0006] Furthermore, an auxiliary fixing clip is clamped between the end of the connecting rod and the permanent magnet rod.
[0007] Furthermore, an auxiliary fixing clip is clamped between the end of the connecting rod and the zirconia ceramic rod.
[0008] Furthermore, it includes a web welded to the bottom plate, and the thickness t of the backing plate: 5 ≤ t ≤ T min / 2, unit mm, T min is the smaller thickness value among the thicknesses of the web and the bottom plate.
[0009] Furthermore, the length a of the backing plate: 300 ≤ a ≤ 2sqrt((R min +1) 2 -R min 2 ), unit mm, R min is the smaller radius value among the radius of the horizontal curve and the radius of the vertical curve of the web when the web is a curved surface.
[0010] Furthermore, the height h of the backing plate: h = δ max +20 and 30 ≤ h ≤ 50, unit mm, δ max is the maximum value of the weld gap.
[0011] The beneficial effects of the present utility model are as follows: First, instead of using a ceramic backing with a relatively high cost, it is made of waste steel sheets that are basically useless, which belongs to the reuse of waste materials, thus reducing the welding cost. Second, the backing itself will not fall off, and the deposited metal has good adhesion, making it easy to weld and reducing the welding difficulty in various welding positions. Third, it has a lower requirement for the dimensional accuracy of the weld gap and has good adaptability to the situation where it is difficult to make the assembly gap of the curved structure completely uniform. Therefore, it has a higher and more stable welding qualification rate than the ceramic backing, reducing the rework rate, thereby reducing the processing cost, welding auxiliary material cost, labor cost, and impact on the construction period caused by rework, and also reducing the increase in safety risks caused by rework and the environmental pollution caused by welding fumes. Fourth, it also belongs to the single-sided welding and double-sided forming welding process, avoiding in-box welding, avoiding adverse working environments, and at the same time avoiding safety risks such as asphyxiation during in-box welding. The present utility model is particularly applicable to the welding process of the main welds of curved steel box bridges. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 It is a schematic diagram of an embodiment of the backing positioning device of the present utility model.
[0013] Figure 2 It is a schematic diagram of the positional relationship between the backing positioning device of the present utility model and the cooperation of the backing plate, the web, and the bottom plate.
[0014] Figure 3 is Figure 2 the perspective view of
[0015] The markings in the figure are: gasket positioning device 10, handle 1, circular sealing plate 2, connecting rod 3, auxiliary fixing clip 4, fixing clip 5, permanent magnet bar 6, zirconia ceramic bar 7, gasket plate 8, web 9, bottom plate 91, gap D. Specific embodiments
[0016] The present utility model will be further described below in conjunction with the accompanying drawings and embodiments.
[0017] As Figure 1 , Figure 2 , Figure 3 shown, it is the specific structure of the gasket positioning device 10 and the cooperation relationship between the gasket positioning device 10, the gasket plate 8, the web 9, and the bottom plate 91. As Figure 1 shown, the gasket positioning device 10 includes a connecting rod 3. The connecting rod 3 is U-shaped and provides basic support during welding. With the U-shaped structure, fixing clips 5 can be arranged at both end parts of the U-shaped structure respectively, that is, fixing clips 5 are provided at both ends of the connecting rod 3. The fixing clip 5 is perpendicular to the end of the connecting rod 3. An oxidation zirconia ceramic bar 7 is provided at the bottom of the fixing clip 5, and a permanent magnet bar 6 is provided at the top of the fixing clip 5. Both the oxidation zirconia ceramic bar 7 and the permanent magnet bar 6 are perpendicular to the fixing clip 5, and the oxidation zirconia ceramic bar 7 and the permanent magnet bar 6 are parallel to the end of the connecting rod 3. The diameter of the oxidation zirconia ceramic bar 7 is equal to the size of the gap D between the bottom of the gasket plate 8 and the bottom plate 91, and the common gap D is 4 - 5 mm. The distance between the centers of the two fixing clips 5 is less than the length of the gasket plate 8. A handle 1 is provided at the bending part of the middle section of the U-shaped connecting rod 3. Among them, the permanent magnet bar 6 and the oxidation zirconia ceramic bar 7 pass through the fixing clip 5 respectively and are then bonded to the auxiliary fixing clip 4. The remaining parts other than the permanent magnet bar 6 and the oxidation zirconia ceramic bar 7 can be selected as Q235B steel and are welded to each other.
[0018] Figure 2As shown in the figure, it is a schematic diagram of an embodiment when the web 9 is welded to the bottom plate 91. Based on the same welding principle, the bottom plate 91 can also be replaced with a top plate, thereby realizing the welding process of the web 9 and the top plate. In this embodiment, the welding of the web 9 and the bottom plate 91 is used to illustrate the corresponding welding structure. During actual operation, hold the handle 1 of the backing positioning device 10 and adjust the angle so that the fixed clamps 5 at both ends of the connecting rod 3 are set on the bottom plate 91, and the bottom edge of the zirconia ceramic rod 7 is tangent to the top surface of the bottom plate 91. The distance between the fixed clamps 5 at both ends of the connecting rod 3 is 1 / 3 of the length of the backing plate 8, and the connecting rod 3 is placed in the middle. The zirconia ceramic rod 7 extends into the bottom of the backing plate by 3 - 5 mm. If it extends too short, the backing plate 8 is likely to fall off; if it extends too long, it is not conducive to the subsequent removal of the backing plate 8. Subsequently, set the lowest edge of the backing plate 8 in the vertical direction on the zirconia ceramic rod 7. At this point, the gap D between the lowest edge of the backing plate 8 and the top surface of the bottom plate 91 is exactly equal to the outer diameter of the zirconia ceramic rod 7, and the zirconia ceramic rod 7 is used to assist in determining the gap D. This way of determining the gap D can avoid the arcing phenomenon that may occur when using welding wires or other metals to assist in determining the gap, thereby preventing the influence on the flatness and cleanliness of the welding surface at the root of the weld. In this embodiment, the outer diameter of the zirconia ceramic rod 7 is 5 mm. Subsequently, place the web 9 tightly against the side of the backing plate 8 in the vertical direction. Then, perform fillet weld spot welding on the side where the backing plate 8 is in contact with the web 9 to fix the backing plate 8 and the web 9 into an integral structure. Generally, it is preferably that the spot welding length 20 mm ≤ L1 ≤ 40 mm, the spacing 250 mm ≤ L ≤ 350 mm, and the fillet weld size 5 mm ≤ h f ≤ t. The common spot welding length is 20 mm, the spacing is 300 mm, and the fillet weld size is 5 mm. The common sizes of the spot welding length, spacing, and fillet weld are the minimum sizes. Smaller sizes are likely to cause the backing to be deformed by heat and fall off during the welding of the main weld. After the backing is welded and fixed, pull out the backing positioning device 10. Finally, blow and clean the lowest edge of the backing plate 8 and the main weld position area between the web 9 and the top surface of the bottom plate 91, and then perform welding on the main weld according to the welding process and parameters evaluated by the welding process. Solid wire, flux-cored wire, gas shielded welding, submerged arc welding, manual welding, robotic welding, etc. can all be used in combination with the corresponding process parameters for welding.
[0019] Regarding the backing plate 8, its material is preferably the same as that of the web 9 and the bottom plate 91. Taking the steel backing plate 8 as an example, its preferred specifications are as follows: the thickness t of the backing plate: 5 ≤ t ≤ T min / 2, in units of mm, T min is the smaller thickness value among the thicknesses of the two base metals of the main weld. If the thickness of the backing plate 8 is too thin, it is easy to burn through during welding; if it is too thick, it may increase the cost and cause waste. The common thicknesses are 5 mm or 8 mm. The length a of the backing plate: 300 ≤ a ≤ 2sqrt((R min +1) 2 -Rmin 2 )), unit: mm, R min When the web 9 is a curved surface, the smaller radius of the flat curve of the web 9 and the vertical curve of the web 9 is used. The length a of the backing plate is determined to control the minimum and maximum values of the plate length when the gap distance deviation between the backing plate 8 and the curved surface base material of the web 9 is between 0 and 1 mm, thereby further improving the welding quality. The height h of the backing plate 8: h = δ max +20 and 30≤h≤50, unit: mm, δ max The maximum value of the weld gap. After the backing plate 8 is cut according to the size, the oxides, burrs, etc. are cleaned and the surface is flat. By limiting the size specifications of the backing plate 8, it is possible to effectively deal with the unfavorable situation that the gap of special-shaped welds such as curves is difficult to be accurately consistent, and it is also suitable for welding welds with larger gaps.
[0020] Example
[0021] Take the main weld welding between the web 9 and the bottom plate 91 of a curved steel box bridge made of Q355C material and 20 mm thick as an example.
[0022] 1. According to the BIM model data and the detailed design drawings, the parts are cut and blanked and the welding grooves are processed. The bottom plate 91, the top plate and the web plate 9 are respectively completed on the ground tire, including the assembly and welding of the respective stiffening ribs of the diaphragm. Through this step, each assembly unit has a good anti-deformation ability. After the production of each assembly unit is completed, the size and weld inspection are required to be qualified.
[0023] 2. Assemble the bottom plate 91, top plate, web plate 9 and diaphragm on the ground tire by the normal assembly method. After the assembly dimensions are checked and qualified, the above components are spot welded and fixed firmly, and the assembly dimensions are checked again to confirm that they are correct. If the unit assembly method is not adopted, but the direct assembly method of parts is adopted, the steel box bridge will be greatly deformed when welding the main weld, which is very unfavorable to the control of the linear shape of the curved steel box bridge after forming.
[0024] 3. During assembly, steel backing plate 8 is made, and it is preferred to use leftover materials for processing, and laser cutting is preferred for cutting. Laser cutting has a smooth cut surface and less oxide. Backing plate 8 is made of Q355C material, which is the same as the parent material, according to the parent material. If the steel box girder with common curve curvature is welded, the specifications of backing plate 8 can be: backing plate 8 thickness 8mm, length 500mm, height 30mm. After cutting and cutting the backing plate 8 according to the controlled size, clean the oxides, burrs, etc., and the surface is flat.
[0025] 4. Install the backing plate 8: Place the backing plate 8 vertically. The right side wall of the backing plate 8 is closely attached to the web 9, and there is a 5-mm gap left between the bottom of the backing plate 8 and the top surface of the bottom plate 91. Use a zirconia ceramic rod 7 with an outer diameter of 5 mm to determine the gap. The distance between the axes of the two zirconia ceramic rods 7 is 150 mm. Spot weld the side of the backing plate 8 that is closely attached to the web 9 with fillet welds to integrate the backing plate 8 and the web 9 into one structure. The length of the spot weld is 20 mm, the spacing is 300 mm, and the leg size is 5 mm. After the backing plate 8 is welded and fixed, pull out the backing plate positioning device 10. At this time, the gap between the bottom of the backing plate 8 and the top surface of the bottom plate 91 is 5 mm.
[0026] 5. Purge and clean the main weld position area between the web 9 and the bottom plate 91.
[0027] 6. Weld the main weld according to the welding process and parameters evaluated by the welding process. Solid wire, flux-cored wire, gas shielded welding, submerged arc welding, manual welding, robotic welding, etc. can all be welded with corresponding process parameters.
[0028] This process method significantly improves the qualified rate of non-destructive testing of the main welds of curved steel box bridges and is applicable to various weld positions. According to experimental tests, under the same welding conditions, when using this technical solution for horizontal welding, vertical welding, and overhead welding positions with single-sided welding and double-sided forming process welding, the average qualified rate of a single welding pass is more than 98%, which is more than 11 percentage points higher than the average qualified rate of 87% in the conventional welding method. Moreover, the deviation of the qualified rate is smaller and the qualified rate is more stable. The increase in the qualified rate means a decrease in the rework rate. When reworking, in addition to consuming the same welding auxiliary materials and working hours, it also increases the consumption of carbon rods, electricity, and labor costs for carbon arc air gouging. The additional working hours for carbon arc air gouging are approximately 1 / 3 of the welding working hours. The reduction of the rework rate also reduces the pollution of the environment by carbon arc air gouging and welding.
Claims
1. Zirconia ceramic rod positioner, including a gasket positioning device (10), characterized in that: The gasket positioning device (10) includes a connecting rod (3). The connecting rod (3) is U-shaped. Fixed clips (5) are provided at both ends of the connecting rod (3). The fixed clips (5) are perpendicular to the ends of the connecting rod (3). A zirconia ceramic rod (7) is provided at the bottom of the fixed clip (5), and a permanent magnet rod (6) is provided at the top of the fixed clip (5). The zirconia ceramic rod (7) and the permanent magnet rod (6) are parallel to the ends of the connecting rod (3). The diameter of the zirconia ceramic rod (7) is equal to the size of the gap (D) between the bottom of the gasket plate (8) and the bottom plate (91). The distance between the centers of the two fixed clips (5) is less than the length of the gasket plate (8). A handle (1) is provided at the bending part of the middle section of the U-shaped connecting rod (3).
2. The zirconia ceramic rod positioner according to claim 1, characterized in that: An auxiliary fixed clip (4) is clamped between the end of the connecting rod (3) and the permanent magnet rod (6).
3. The zirconia ceramic rod positioner according to claim 2, wherein: An auxiliary fixed clip (4) is clamped between the end of the connecting rod (3) and the zirconia ceramic rod (7).
4. The zirconia ceramic rod positioner according to any one of claims 1 to 3, characterized in that: It includes a web (9) welded to a bottom plate (91), and the thickness t of the backing plate (8) satisfies 5 ≤ t ≤ T min / 2, with the unit of mm, and T min is the smaller value of the thicknesses of the web (9) and the bottom plate (91).
5. The zirconia ceramic rod positioner according to claim 4, characterized in that: Length a of the backing plate (8): 300 ≤ a ≤ 2√((R min + 1) 2 - R min 2 )), unit: mm, where R min is the smaller value of the radius of the horizontal curve and the vertical curve of the web (9) when the web (9) is a curved surface.
6. The zirconia ceramic rod positioner as described in claim 5, characterized in that: Height h of the backing plate: h = δ max +20 and 30 ≤ h ≤ 50, unit: mm, where δ max is the maximum value of the weld gap.