Quick butt welding equipment for PVC (polyvinyl chloride) pipes

Abstract

The utility model discloses quick butt welding equipment for PVC (polyvinyl chloride) pipes, which comprises a base, a heating module, a clamping mechanism and a control system, guide rollers with V-shaped grooves are arranged at two ends of the base, and the quick butt welding equipment can adapt to axial positioning of different pipe diameters; the heating module is of a vertically symmetrical heating block structure, the inner surface of the heating module is covered with an elastic heat conduction pad, independent temperature control heating units are evenly distributed in the circumferential direction of the interior of the heating module, and accurate pressure control is achieved through a driving air cylinder. The clamping mechanism is provided with a bidirectional lead screw to drive a synchronously adjusted fixing clamp and is combined with a laser centering sensor to realize automatic alignment of the end face of the pipeline; the control system integrates temperature, pressure and photoelectric sensing modules and monitors welding parameters in real time. The equipment has the characteristics of rapid remodeling and multi-specification compatibility, the welding quality is improved through partition temperature control and a flexible heat conduction structure, and the problems that traditional PVC pipe welding is low in efficiency and large in alignment deviation are effectively solved.

Description

Technical Field

[0001] This utility model relates to the field of butt welding of plastic pipes, and in particular to a rapid butt welding device for PVC pipes. Background Technology

[0002] As a core material in municipal engineering and building water supply and drainage, the welding quality of PVC pipes directly affects the sealing performance and service life of the pipeline system. Traditional hot-melt butt welding equipment generally suffers from the following technical bottlenecks: 1. Low temperature control accuracy: Conventional heating blocks use integral heating units, which cannot adapt to the welding requirements of different pipe diameters, easily causing uneven heating at the pipe ends, resulting in differences in the thickness of the molten layer (usually >0.5mm), and the welding interface is prone to porosity or incomplete welds; 2. Low centering adjustment efficiency: Relying on manual visual calibration, the adjustment time is as long as 3-5 minutes / time, and the axial deviation is generally >1mm, which seriously affects the concentricity of the weld; 3. Poor equipment versatility: Fixed clamping mechanisms are difficult to be compatible with irregularly shaped pipes (such as square pipes and oval pipes), and changing to special clamps takes more than 15 minutes.

[0003] Existing technologies, such as Chinese patent publication number CN115008757A, propose a high-precision plastic pipe welding device that can weld multiple pipes in sequence and quickly, but it still does not solve core problems such as multi-diameter adaptive temperature control. Utility Model Content

[0004] The technical problem to be solved by this utility model is to overcome the defects of the prior art and provide a rapid butt welding device for PVC pipes.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0006] This utility model discloses a rapid butt welding device for PVC pipes, comprising: a base with guide rollers at both ends, the guide rollers having V-shaped grooves on their surfaces to guide the axial movement of pipes of different diameters; a heating module consisting of two heating blocks arranged vertically opposite each other, the inner surface of each heating block having an elastic heat-conducting pad, and multiple independently temperature-controlled heating units equidistantly embedded circumferentially inside, the power supply lines of the heating units passing through a heat insulation plate and connected to a controller; a piston rod of a drive cylinder detachably connected to the bottom of the heating blocks via a heat insulation plate made of ceramic fiber composite material; a clamping mechanism consisting of brackets symmetrically arranged on both sides of the heating blocks, with a sliding rod fixed inside the bracket, and two sets of coaxial circular clamps slidably connected to the sliding rod, the inner walls of the clamps having anti-slip textures; an adjustment mechanism consisting of a drive motor connected to a bidirectional lead screw via a coupling, the positive and negative thread sections of the lead screw being linked to the two sets of clamps respectively; and a control system comprising a controller, a temperature sensor embedded in the heating blocks, a pressure sensor installed at the end of the piston rod of the drive cylinder, and a laser alignment sensor located on the side of the bracket.

[0007] As a preferred technical solution of this utility model, the heating unit of the heating block is divided into three independently temperature-controlled arc-shaped partitions along the circumference. The heating units of each partition are distributed at equal angular intervals, and the elastic heat-conducting pad is a flexible structure of silicone substrate composite metal mesh, with the metal mesh extending to the edge of the heating block to form a grounding terminal.

[0008] As a preferred technical solution of this utility model, the piston rod end of the drive cylinder is provided with a pressure buffer assembly, including a disc spring and a rubber damping block coaxially sleeved, wherein the elastic coefficient of the disc spring is matched with the weight of the heating block.

[0009] As a preferred technical solution of this utility model, the transmitting end and receiving end of the laser alignment sensor are located on both sides of the bracket to form a cross laser beam. The controller generates a pipe offset signal according to the blocking position of the laser beam and controls the drive motor to adjust the rotation direction of the lead screw.

[0010] As a preferred technical solution of this utility model, the heating block is provided with a detachable heat insulation cover on the outside. The heat insulation cover is made of a composite of a glass fiber cloth outer layer and an aluminum foil inner layer, and the top is connected to the piston rod of the driving cylinder through a sliding buckle structure.

[0011] As a preferred technical solution of this utility model, the clamping surface of the fixing clamp is provided with a photoelectric sensor. When the controller detects that the end of the pipe has not reached the set position, it prohibits the driving cylinder from starting the downward pressing action of the heating block.

[0012] As a preferred technical solution of this utility model, the heating block can be replaced with a polygonal heating block that matches the cross-section of the pipe to be welded. When replacing, only the connecting bolts of the heat insulation plate need to be removed.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] 1. The heating unit with independent temperature control in three circumferential zones (temperature deviation ≤5℃) combined with the elastic heat-conducting pad can adapt to pipe diameters of Φ50-200mm, improving the uniformity of the molten layer thickness to over 92%; the three-stage temperature control algorithm (preheating-melting-pressure holding) reduces the range of the welding heat-affected zone by 40%, avoiding excessive softening and deformation of the pipe.

[0015] 2. The cross laser centering sensor is linked with the bidirectional lead screw to achieve automatic compensation for axial deviation (accuracy ±0.1mm), and the centering adjustment time is shortened to within 20 seconds; the photoelectric interlocking mechanism of the clamping mechanism ensures that the tube end positioning error is <0.5mm, and prevents the heating block from running unloaded.

[0016] 3. The modular heating block design supports welding of irregular cross-sections such as hexagonal / square tubes, and the replacement time is less than 3 minutes; the V-shaped guide roller and the bidirectional adjustable clamping mechanism work together to be compatible with various materials such as PVC and CPVC with wall thickness of 2-15mm. Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0019] Figure 2 This is the front view of this utility model;

[0020] Figure 3 This is a top view of the present invention;

[0021] Figure 4 This is a side view of the present invention;

[0022] Figure 5 This is a schematic diagram of the heating module in this utility model;

[0023] In the diagram: 1. Base; 2. Heating module; 3. Clamping mechanism; 11. Guide roller; 21. Heating block; 22. Elastic heat-conducting pad; 23. Heating unit; 24. Heat insulation plate; 25. Drive cylinder; 26. Heat insulation cover; 27. Pressure buffer assembly; 31. Bracket; 32. Slide rod; 33. Fixing clamp; 34. Drive motor; 35. Lead screw; 36. Photoelectric sensor; 41. Controller; 42. Temperature sensor; 43. Pressure sensor; 44. Laser alignment sensor. Detailed Implementation

[0024] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0025] In the attached diagram, all identical reference numerals refer to the same components.

[0026] like Figure 1-5 As shown, this utility model provides a rapid butt welding device for PVC pipes, comprising the following main structure:

[0027] Base and guiding mechanism: The base 1 is a rectangular steel plate structure, with guide rollers 11 fixed to both ends by bolts. The guide rollers 11 are hollow steel rollers with V-shaped grooves machined on the surface, and rubber anti-slip strips are embedded in the grooves. The guide rollers 11 are connected to the base 1 through bearings and can rotate freely around their axis, used to support PVC pipes of different diameters and guide their axial movement.

[0028] The heating module 2 includes two symmetrically arranged heating blocks 21, each made of aluminum alloy with an elastic thermal conductive pad 22 bonded to its inner surface. The elastic thermal conductive pad 22 has a sandwich structure of silicone layer and copper mesh, with the copper mesh extending to the side of the heating block 21 to form a grounding terminal. Three independent arc-shaped sections are evenly distributed circumferentially inside the heating block 21, each section containing six sets of ceramic heating units 23. The heating units 23 are connected to the controller 41 via high-temperature resistant wires passing through a ceramic fiber insulation plate 24. The piston rod end of the drive cylinder 25 is fixed to the insulation plate 24 via a flange, and the other side of the insulation plate 24 is detachably connected to the bottom of the heating block 21 via a snap-fit ​​structure.

[0029] The clamping mechanism 3 includes brackets 31 symmetrically arranged on both sides of the heating block 21. Each bracket 31 has a U-shaped steel frame structure with two parallel sliding rods 32 welded inside. Two sets of coaxial circular clamps 33 are mounted on the sliding rods 32. The inner wall of each clamp 33 is machined with a fish-scale anti-slip texture, and the outer ring is fitted with a self-locking ball bearing slider. The adjustment mechanism includes a drive motor 34 mounted at the end of the brackets 31. The drive motor 34 is connected to a bidirectional lead screw 35 via a flexible coupling. The forward and reverse threaded sections of the lead screw 35 respectively engage with the sliders of the two sets of clamps 33, achieving synchronous adjustment of the clamping distance.

[0030] The control system integrates the controller 41 within the equipment side housing. Three sets of armored temperature sensors 42 are embedded inside the heating block 21, with the sensor probes arranged close to the surface of the heating unit 23. A pressure sensor 43 is installed at the end of the piston rod of the drive cylinder 25; the sensor 43 is threadedly connected between the end of the piston rod and the heat insulation plate 24. A laser alignment sensor 44 is installed on the side of the bracket 31, with the transmitter and receiver located at the top of the columns of the left and right brackets 31, forming a cross-shaped laser beam. A photoelectric sensor 36 is embedded inside the clamping surface of the fixing clamp 33 to detect the positioning of the pipe end.

[0031] A pressure buffer assembly 27 is installed at the end of the piston rod of the drive cylinder 25. The assembly 27 includes a coaxially mounted disc spring and a nitrile rubber damping block. The preload of the disc spring is set by an adjusting nut. The heating block 21 is wrapped with a removable heat insulation cover 26, which is made of an outer layer of fiberglass woven fabric and an inner layer of aluminum foil. The top of the heat insulation cover is slidably connected to the piston rod of the drive cylinder 25 via a sliding buckle structure. Each heating unit 23 has an independent overload protection switch for its power supply line, and the grounding terminal is connected to the metal frame of the equipment via a braided copper cable.

[0032] This implementation achieves rapid changeover through modular design. When dealing with irregularly shaped pipes, only the connecting bolts of the heat insulation plate 24 need to be removed to replace the polygonal heating block 21. During operation, the laser alignment sensor 44 monitors the pipe axis offset in real time, and the controller 41 controls the drive motor 34 to adjust the position of the fixing clamp 33 according to the offset signal to ensure precise alignment of the welding end face.

[0033] This invention relates to a rapid butt welding device for PVC pipes. The heating module features independently temperature-controlled arc-shaped zones and elastic heat-conducting pads, adapting to different pipe diameters and ensuring uniform heating. The clamping mechanism is adjusted via a bidirectional screw, working in conjunction with a laser alignment sensor to achieve precise positioning. The drive cylinder incorporates a pressure buffer component to prevent overpressure. The heating blocks are replaceable to accommodate pipes of different shapes. This equipment improves welding efficiency and quality, and is safe and reliable to operate.

[0034] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model 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 this utility model should be included within the protection scope of this utility model.

Claims

1. A rapid butt welding device for PVC pipes, characterized in that, include: The base (1) has guide rollers (11) at both ends. The roller surface of the guide rollers (11) has a V-shaped groove for guiding the axial movement of pipes of different diameters. The heating module (2) consists of two heating blocks (21) arranged opposite each other in the vertical direction. The inner surface of the heating block (21) is provided with an elastic heat-conducting pad (22), and multiple independent temperature-controlled heating units (23) are embedded equidistantly in the circumferential direction. The power supply line of the heating unit (23) passes through the heat insulation plate (24) and is connected to the controller (41). The piston rod of the drive cylinder (25) is detachably connected to the bottom of the heating block (21) through the heat insulation plate (24) made of ceramic fiber composite material. The clamping mechanism (3) is symmetrical. The brackets (31) are set on both sides of the heating block (21). A slide rod (32) is fixed inside the bracket (31). Two sets of coaxial circular fixing clamps (33) are slidably connected on the slide rod (32). The inner wall of the fixing clamp (33) is provided with anti-slip texture. Adjustment mechanism: The drive motor (34) is connected to the bidirectional lead screw (35) through the coupling. The positive and negative thread sections of the lead screw (35) are linked with the two sets of fixing clamps (33) respectively. Control system: Includes a controller (41), a temperature sensor (42) embedded in the heating block (21), a pressure sensor (43) installed at the end of the piston rod of the drive cylinder (25), and a laser centering sensor (44) set on the side of the bracket (31).

2. The PVC pipe rapid butt welding equipment according to claim 1, characterized in that, The heating unit (23) of the heating block (21) is divided into three independently temperature-controlled arc-shaped partitions along the circumference. The heating units (23) of each partition are distributed at equal angles. The elastic heat-conducting pad (22) is a flexible structure of silicone substrate composite metal mesh. The metal mesh extends to the edge of the heating block (21) to form a grounding terminal.

3. The PVC pipe rapid butt welding equipment according to claim 1, characterized in that, The piston rod end of the drive cylinder (25) is provided with a pressure buffer assembly (27), which includes a disc spring and a rubber damping block coaxially sleeved together. The elastic coefficient of the disc spring is matched with the weight of the heating block (21).

4. The PVC pipe rapid butt welding equipment according to claim 1, characterized in that, The transmitter and receiver of the laser alignment sensor (44) are located on the two side brackets (31) respectively, forming a cross laser beam. The controller (41) generates a pipe offset signal according to the blocking position of the laser beam and controls the drive motor (34) to adjust the rotation direction of the lead screw (35).

5. The rapid butt welding equipment for PVC pipes according to claim 1, characterized in that, The heating block (21) is provided with a detachable heat insulation cover (26) on the outside. The heat insulation cover (26) is made of a composite of a glass fiber cloth outer layer and an aluminum foil inner layer. The top is connected to the piston rod of the drive cylinder (25) through a sliding buckle structure.

6. The rapid butt welding equipment for PVC pipes according to claim 1, characterized in that, The clamping surface of the fixing clamp (33) is equipped with a photoelectric sensor (36). When it is detected that the end of the pipe has not reached the set position, the controller (41) prohibits the drive cylinder (25) from starting the pressing action of the heating block (21).

7. The rapid butt welding equipment for PVC pipes according to claim 1, characterized in that, The heating block (21) can be replaced with a polygonal heating block (21) that matches the cross section of the pipe to be welded. When replacing, only the connecting bolts of the heat insulation plate (24) need to be removed.

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