A welding machine for deep hole wire break-out
By designing a welding machine for removing broken wires from deep holes, and using a combination of drive components and welding mechanisms, automated welding was achieved, solving the problem of difficult removal of broken bolts from deep holes in wind turbine blades, and improving ease of operation and efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- BEIJING CENTURY CONCORD OPERATION & MAINTENANCE CO LTD
- Filing Date
- 2025-07-08
- Publication Date
- 2026-06-19
Smart Images
Figure CN224373161U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of welding machine technology, and in particular to a welding machine for removing broken wires from deep holes. Background Technology
[0002] After years of operation, the high-strength bolts that fix the pitch bearings and blades of wind turbine generator sets are prone to breakage. Depending on the model, most bolt breakage occurs in the deep holes of 350-450mm on the flange surface of the blade body. Therefore, personnel need to remove and replace the broken bolts to ensure the normal and safe operation of the wind turbine generator set.
[0003] Existing technology involves drilling a center hole of appropriate diameter in the center of the stud that broke inside the deep hole of the wind turbine blade, and then using an extended rod reverse wire extractor to remove the broken wire.
[0004] Regarding the above-mentioned and existing related technologies, the inventors believe that the following defects often exist: on the one hand, the process requires the use of tools such as magnetic drills and extended drill bits, which makes it inconvenient to carry and maintain them at high altitudes; on the other hand, the fastening adhesive and rust applied to the outside of the bolts make removal difficult, resulting in a long time required to remove a single broken wire, leading to low work efficiency and poor economic performance. Utility Model Content
[0005] The technical problem to be solved by this utility model is that the existing technology has the disadvantage of not being convenient to quickly remove broken bolts. To this end, we propose a welding machine for removing broken wires from deep holes.
[0006] To achieve the above objectives, this application adopts the following technical solution: a welding machine for extracting broken wires in deep holes, comprising a drive assembly, a probe clamping head threaded on the outer side of the drive assembly, a welding rod chuck at one end of the drive assembly, a welding mechanism one on the inner side of the probe clamping head, and a welding mechanism two on the inner side of the welding rod chuck; the welding mechanism one includes a welding rod probe, a welding rod at one end of the welding rod probe, threaded grooves on the outer walls of the ends of the welding rod probe and the welding rod that are close to each other, and standard threads are fitted on the outer threads of the ends of the welding rod probe and the welding rod that are close to each other; the welding mechanism two includes an extended welding rod, the inner diameter of which is larger than the diameter of the welding rod probe and the welding rod. First, a center hole of appropriate diameter is drilled in the center of the broken wire stud using a tool. Then, an extended welding rod of appropriate length is selected according to the depth of the broken wire hole to meet the space required for subsequent operations. Then, one end of the welding rod probe is passed through the probe clamping head, and the probe clamping head clamps and fixes the welding rod probe, and the standard threads are fitted on the outer walls of one end of the welding rod probe. Next, connect one end of the welding rod to the standard threaded connection. Then, pass the extended welding rod through the welding rod chuck and place it on the outside of the welding rod. Use the welding rod chuck to clamp and fix the extended welding rod. At this time, move the entire device so that the welding end of the extended welding rod abuts against the wall of the broken wire stud hole. The main control box can then control the drive assembly to move the probe tip horizontally until the welding rod end face is mm away from the extended welding rod end face. This effectively avoids friction and collision between the welding rod and the broken wire stud hole wall, which could cause the welding rod end to break. Deformation and coating peeling affect the stability of the arc and the quality of the weld during welding. Finally, by connecting the negative electrode of the welding machine to the welding rod and the positive electrode to the extended welding rod, the automatic and efficient welding of the extended welding rod and the broken wire stud can be achieved. The main control box and welding machine are existing technologies in this field, and will not be elaborated on here. It solves the problems of bulky tools, high technical threshold, poor applicability and low efficiency. It can also shorten the time for removing broken wires by means of precise positioning and automatic welding. At the same time, it uses high temperature to destroy the bolt locking glue and rust layer.
[0007] Preferably, multiple wedges are arranged in a circular pattern on the outer wall of the welding end of the extended welding rod. The vertical surface of the wedges abuts against the outer wall of the extended welding rod, and an inclined surface is provided on the side of the wedge away from the extended welding rod. When the wedge enters between the extended welding rod and the hole wall, the contact between the inclined surface and the hole wall generates radial pressure, thereby keeping the extended welding rod in a centered position and preventing it from shifting during welding. Furthermore, anti-slip textures can be provided on the surface of the wedges to further enhance the friction with the extended rod and the hole wall, preventing loosening after fixing.
[0008] Preferably, the outer side of the extended welding rod is provided with multiple sets of cooling thin copper tubes and PT100 probes. The cooling thin copper tubes are bolted to the external pipes. The cooling thin copper tubes and PT100 probes can be used to cool and measure the temperature of the local welding area, thereby controlling the temperature and avoiding damage to the surrounding structure.
[0009] Preferably, the cooling thin copper tube and the PT100 probe are wrapped with fiberglass cloth tape. During the welding process, the welding end of the extended welding rod has a high temperature. By wrapping the cooling thin copper tube and the PT100 probe with fiberglass cloth, the melting or carbonization caused by the welding heat is prevented. This ensures that the cooling thin copper tube and the PT100 probe remain fixed in a high-temperature environment, preventing them from falling off and affecting the temperature control of the welding process. In addition, after the fiberglass cloth tape is soaked in water, it can absorb the heat on the surface of the extended welding rod through water evaporation, which helps to enhance the heat dissipation efficiency of the cooling thin copper tube.
[0010] Preferably, the drive assembly includes a stepper motor bolted to the working surface, a lead screw fixedly mounted on the drive end of the stepper motor, and a support plate fixedly mounted on the lower end of the stepper motor. The probe tip includes a slider threadedly connected to the lead screw, and the slider is slidably connected to the support plate. Through the cooperation of the stepper motor and the lead screw, the drive assembly can precisely control the horizontal movement of the probe tip. The sliding guide of the slider by the support plate ensures stable movement without deviation. The overall structure not only achieves precise adjustment of the position of the welding rod probe, meeting the positioning requirement of the welding rod end face being mm away from the extended welding rod end face, but also improves the automation level of the welding process by virtue of the CNC characteristics of the stepper motor, making the equipment easier to operate and with higher positioning accuracy.
[0011] Preferably, a chuck is bolted to one side of the upper end of the slider to enable rapid detection and fixation of the welding rod probe.
[0012] The technical effects and advantages of this utility model are as follows: It can effectively avoid friction and collision between the welding rod and the hole wall of the broken wire stud, which would cause deformation of the welding rod end and peeling of the coating, affecting the arc stability and deposition quality during welding. It can realize automatic and efficient welding of the extended welding rod and the broken wire stud, and solve the problems of heavy tools, high technical threshold, poor applicability and low efficiency. It can also shorten the time for removing broken wires by means of precise positioning and automatic welding, and at the same time use high temperature to destroy the bolt locking glue and rust layer. In this invention, firstly, a center hole of appropriate diameter is drilled in the center of the broken wire stud using a tool. Then, an extended welding rod of appropriate length is selected according to the depth of the broken wire hole to meet the space required for subsequent operations. Next, one end of the welding rod probe is passed through the probe clamp and clamped and fixed by the probe clamp. The standard thread is sleeved on the outer wall of one end of the welding rod probe. Then, one end of the welding rod is connected to the standard thread. Subsequently, the extended welding rod is passed through the welding rod chuck and sleeved on the outside of the welding rod. The extended welding rod is clamped and fixed by the welding rod chuck. At this time, the entire device is moved so that the welding end of the extended welding rod abuts against the wall of the broken wire stud hole. The drive component is then controlled by the main control box to drive the probe clamp to move horizontally until the end face of the welding rod is mm away from the end face of the extended welding rod. Finally, the negative terminal of the welding machine is connected to the welding rod probe and the positive terminal is connected to the extended welding rod. Attached Figure Description
[0013] The disclosure of this utility model is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this utility model. In the drawings, the same reference numerals are used to refer to the same parts: Figure 1 This is a schematic diagram of the overall structure of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the overall structure of the present invention. Figure 2 ; Figure 3 This is an exploded view of the drive assembly and probe tip structure of this utility model. Figure 4 This is an exploded view of the welding rod chuck structure of this utility model; Figure 5 This is an exploded view of the welding mechanism of this utility model.
[0014] Legend: 1. Drive assembly; 11. Stepper motor; 12. Lead screw; 14. Support plate; 2. Probe tip; 21. Slider; 22. Chuck II; 3. Welding rod chuck; 4. Welding mechanism I; 41. Welding rod probe; 42. Welding rod; 43. Threaded groove; 44. Standard thread; 5. Welding mechanism II; 51. Extended welding rod; 52. Wedge; 53. Cooling thin copper tube; 54. PT100 probe; 55. Fiberglass cloth tape. Detailed Implementation
[0015] It is readily understood that, based on the technical solution of this utility model, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of this utility model. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative descriptions of the technical solution of this utility model and should not be considered as the entirety of this utility model or as limitations or restrictions on the technical solution of this utility model.
[0016] Reference Figure 1-2 , Figure 4-5As shown, this utility model provides a technical solution: a welding machine for removing broken wires in deep holes, including a drive assembly 1, a probe clamp 2 threaded on the outer side of the drive assembly 1, a welding rod chuck 3 at one end of the drive assembly 1, a welding mechanism 1 4 on the inner side of the probe clamp 2, and a welding mechanism 2 5 on the inner side of the welding rod chuck 3; the welding mechanism 1 4 includes a welding rod probe 41, a welding rod 42 at one end of the welding rod probe 41, and threaded grooves 43 on the outer walls of the ends of the welding rod probe 41 and the welding rod 42 that are close to each other; the welding rod probe 41 and the welding rod 42 are connected by a welding rod probe 41 and a welding rod 42. 42. The outer side of the two ends approaching each other is threaded with a standard thread 44; the welding mechanism 2 5 includes an extended welding rod 51, the inner diameter of which is larger than the diameter of the welding rod probe 41 and the welding rod 42. First, a center hole of appropriate diameter is drilled in the center of the broken wire stud using a tool. Then, an extended welding rod 51 of appropriate length is selected according to the depth of the broken wire hole to meet the space required for subsequent operations. Then, one end of the welding rod probe 41 is passed through the probe clamp 2 and clamped and fixed by the probe clamp 2. The standard thread 44 is threaded onto the welding rod probe. One end of the rod 41 is attached to the outer wall, and then one end of the welding rod 42 is threaded to the standard thread 44. The extended welding rod 51 is then passed through the welding rod chuck 3 and fitted onto the outside of the welding rod 42. The extended welding rod 51 is clamped and fixed using the welding rod chuck 3. The entire device is then moved so that the welding end of the extended welding rod 51 abuts against the wall of the broken wire stud hole. The drive assembly 1, controlled by the main control box, then moves the probe head 2 horizontally until the end face of the welding rod 42 is 5mm from the end face of the extended welding rod 51. This effectively prevents the welding rod 42 from contacting the wall of the broken wire stud hole. Friction and collision cause deformation and coating peeling at the end of the welding rod 42, affecting the arc stability and deposition quality during welding. Finally, by connecting the negative electrode of the welding machine to the welding rod probe 41 and the positive electrode to the extended welding rod 51, the automatic and efficient welding of the extended welding rod 51 and the broken wire stud can be achieved. The main control box and welding machine are existing technologies in this field, and will not be elaborated on here. It solves the problems of bulky tools, high technical threshold, poor applicability and low efficiency. It can also shorten the time for removing broken wires by means of precise positioning and automatic welding, and at the same time use high temperature to destroy the bolt locking glue and rust layer.
[0017] Reference Figure 5 As shown in this embodiment: multiple wedges 52 are installed in a circular arrangement on the outer wall of the welding end of the extended welding rod 51. The vertical surface of the wedge 52 abuts against the outer wall of the extended welding rod 51. An inclined surface is opened on the side of the wedge 52 away from the extended welding rod 51. When the wedge 52 enters between the extended welding rod 51 and the hole wall, the contact between the inclined surface and the hole wall generates radial pressure, thereby keeping the extended welding rod 51 in a centered position and avoiding displacement during welding. Furthermore, anti-slip textures can be opened on the surface of the wedge 52 to further enhance the friction with the extended rod and the hole wall, preventing loosening after fixing.
[0018] Reference Figure 5As shown in this embodiment: multiple sets of cooling thin copper tubes 53 and PT100 probes 54 are provided on the outer side of the extended welding rod 51. The cooling thin copper tubes 53 are bolted to the external pipes. The cooling thin copper tubes 53 and PT100 probes 54 can be used to cool and measure the temperature of the local welding area, thereby controlling the temperature and avoiding damage to the surrounding structure.
[0019] Reference Figure 5 As shown in this embodiment: the outer sides of the cooling thin copper tube 53 and the PT100 probe 54 are wrapped with fiberglass cloth tape 55. During the welding process, the welding end of the extended welding rod 51 has a high temperature. The fiberglass cloth tape wraps the cooling thin copper tube 53 and the PT100 probe 54 to prevent them from melting or carbonizing due to the welding heat. This ensures that the cooling thin copper tube 53 and the PT100 probe 54 remain fixed in the high-temperature environment, preventing them from falling off and affecting the temperature control of the welding process. In addition, after the fiberglass cloth tape is soaked in water, it can absorb the heat on the surface of the extended welding rod 51 through water evaporation, which helps to enhance the heat dissipation efficiency of the cooling thin copper tube 53.
[0020] Reference Figure 3 As shown in this embodiment: the drive assembly 1 includes a stepper motor 11 bolted to the working surface, a lead screw 12 fixedly mounted on the drive end of the stepper motor 11, and a support plate 14 fixedly mounted on the lower end of the stepper motor 11. The probe head 2 includes a slider 21 threadedly connected to the lead screw 12. The slider 21 is slidably connected to the support plate 14. The drive assembly 1 can precisely control the horizontal movement of the probe head 2 through the cooperation of the stepper motor 11 and the lead screw 12. The sliding guide of the support plate 14 on the slider 21 ensures that the movement process is stable and without deviation. The overall structure not only realizes the precise adjustment of the position of the welding rod probe 41 and meets the positioning requirement of 5mm between the end face of the welding rod 42 and the end face of the extended welding rod 51, but also improves the automation of the welding process with the CNC characteristics of the stepper motor 11, making the equipment operation simpler and the positioning accuracy higher.
[0021] Reference Figure 3 As shown in this embodiment: a chuck 22 is bolted to one side of the upper end of the slider 21, which can quickly detect and fix the welding rod probe 41.
[0022] Working principle: First, a center hole of appropriate diameter is drilled in the center of the broken wire stud using a tool. Then, an extended welding rod 51 of appropriate length is selected according to the depth of the broken wire hole to meet the space required for subsequent operations. Next, one end of the welding rod probe 41 is passed through the probe clamp 2 and clamped and fixed by the probe clamp 2. The standard thread 44 is threaded onto the outer wall of one end of the welding rod probe 41. Then, one end of the welding rod 42 is threaded to the standard thread 44. Subsequently, the extended welding rod 51 is passed through the welding rod chuck 3 and fitted onto the outside of the welding rod 42. The extended welding rod 51 is clamped and fixed by the welding rod chuck 3. At this time, the entire device is moved so that the welding end of the extended welding rod 51 abuts against the wall of the broken wire stud hole. The drive assembly 1 can then be driven by the main control box. The probe tip 2 is moved horizontally until the end face of the welding rod 42 is 5mm away from the end face of the extended welding rod 51. This effectively avoids friction and collision between the welding rod 42 and the hole wall of the broken wire stud, which could cause deformation of the end of the welding rod 42 and coating peeling, affecting the arc stability and deposition quality during welding. Finally, the negative terminal of the welding machine is connected to the welding rod probe 41 and the positive terminal is connected to the extended welding rod 51, thus achieving automatic and efficient welding of the extended welding rod 51 and the broken wire stud. After welding, the welding machine cable is removed, the probe tip 2 and the welding rod chuck 3 are loosened, the welding mechanism 4 is pulled out from the extended welding rod 51, the cooling thin copper tube 53 and the PT100 probe 54 are pulled out, and the extended welding rod 51 with the broken wire end is unscrewed with pipe wrenches. The extended welding rod 51 can be cut with an angle grinder and reused until its length is insufficient for the hole depth and it is scrapped. After the broken wire removal is completed, a new bolt is installed to restore the fault, and the tools are cleaned and the work surface is tidied.
[0023] The technical scope of this utility model is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this utility model, and all such modifications and variations should fall within the protection scope of this utility model.
Claims
1. A welding machine for removing broken wires from deep holes, characterized in that, The device includes a drive assembly, on the outer side of which a probe chuck is threaded. One end of the drive assembly has a welding rod chuck. The inner side of the probe chuck has a first welding mechanism, and the inner side of the welding rod chuck has a second welding mechanism. The first welding mechanism includes a welding rod probe, one end of which has a welding rod attached. Both the outer walls of the probing ends and the welding rod, which are close to each other, have threaded grooves. The outer threads of the probing ends and the welding rod, which are close to each other, are fitted with standard threads. The second welding mechanism includes an extended welding rod, the inner diameter of which is larger than the diameter of the probing ends and the welding rod.
2. The welding machine for removing broken wires in deep holes according to claim 1, characterized in that: The welding end of the extended welding rod has multiple wedges arranged in a circular pattern on its outer wall. The vertical surface of each wedge abuts against the outer wall of the extended welding rod, and an inclined surface is provided on the side of each wedge away from the extended welding rod.
3. The welding machine for removing broken wires in deep holes according to claim 1, characterized in that: The extended welding rod is provided with multiple sets of cooling thin copper tubes and PT100 probes on its outer side, and the cooling thin copper tubes are bolted to the external pipeline.
4. A welding machine for removing broken wires in deep holes according to claim 3, characterized in that: The cooling thin copper tube and the PT100 probe are wrapped with glass fiber cloth tape.
5. A welding machine for removing broken wires in deep holes according to claim 1, characterized in that: The drive assembly includes a stepper motor bolted to the working face, a lead screw fixedly mounted on the drive end of the stepper motor, a support plate fixedly mounted on the lower end of the stepper motor, and a probe head including a slider threadedly connected to the lead screw, the slider being slidably connected to the support plate.
6. A welding machine for removing broken wires in deep holes according to claim 5, characterized in that: A chuck is bolted to one side of the upper end of the slider.