An apparatus for preparing a flux tape for ultra-narrow gap welding

Abstract

The utility model discloses a kind of flux tape preparation devices of ultra-narrow gap welding, it is related to flux tape preparation technical field.The utility model includes carrier, and the carrier is equipped with vibration disc and wire hoop, further includes: mould cylinder, at least one spiral limiting slot is set on its circumferential surface.The utility model is set on the circumferential surface of mould cylinder multiple spiral limiting slots, and make mould cylinder and the front end of transmission mechanism realize concentric rotation, so that mould cylinder can be continuously formed and accommodate lengthier flux tape once.Dispensing mechanism adopts mature screw rod drive, high stability, easy to manufacture, so that mould cylinder can be moved along screw rod axial while rotating, so that spiral limiting slot can continuously, uninterruptedly form and accommodate longer flux tape, effectively improve manufacturing efficiency and product length.

Description

Technical Field

[0001] This utility model belongs to the field of flux strip preparation technology, and more specifically, it relates to a flux strip preparation device for ultra-narrow gap welding. Background Technology

[0002] Flux-confined arc welding with ultra-narrow gaps is an advanced welding method characterized by high efficiency and low heat input. This method typically employs a 4–6 mm I-groove and utilizes a plate welding torch and a specially designed flux strip to physically confine the welding arc, ensuring its stable action on both sides and the bottom of the groove, thereby achieving high-quality single-pass multi-layer weld formation. The core of this technology lies in shaping and stabilizing the arc morphology through the flux strip. Its process characteristics are reflected in the ability to flexibly control the arc heat input by adjusting the flux strip thickness and feed speed. Therefore, the quality of the flux strip itself and its batch stability have a decisive impact on the arc confinement effect and weld quality.

[0003] Chinese patent CN102896399B discloses an ultra-narrow gap arc welding device for rail butt welding. The disclosed flux strip consists of a wire mesh and flux sheets coated on both sides, which need to be bent and placed into the bevel before welding. The problem is that the middle part of the wire mesh is exposed, and the arc first contacts the wire mesh to conduct electricity during welding. If there are uncoated portions of the wire mesh attached to the sidewalls, a conductive channel will be formed with the sidewalls, causing the arc to rise. Furthermore, the flux strip is pre-placed and needs to be manually bent before welding, which can easily lead to the flux strip not adhering to the sidewalls within the bevel, making post-weld slag removal difficult and even damaging the welding torch.

[0004] Chinese patent CN105478973B discloses an ultra-narrow gap arc welding device for feeding flux sheet chains. It uses high-temperature resistant adhesive to attach high-temperature resistant elastic ropes to the sides of the flux sheets, creating flux sheet chains with planar deformation capabilities. The problems with this device are: the lack of a systematic preparation apparatus leads to a long preparation cycle for the flux sheet chains, and the quality of manual preparation is difficult to guarantee. During the welding process, if the quality of the manually prepared flux strip is poor, it will lead to a decrease in the quality of the weld joint, and there are risks such as burning out the welding torch and delaying the project schedule.

[0005] Chinese patent CN114734163A describes a method for ultra-narrow gap welding of ribbons by butt-fitting two halves of flux pieces together and then bonding them with a top spring. However, it suffers from the following problems: The manufacturing process is cumbersome, requiring the butt joint of the halves before bonding the spring, resulting in low efficiency; the conveying process is easily obstructed, as the square-structured halves are prone to misalignment or jamming in the mold cylinder's threaded groove, affecting the bonding effect; and the structure has poor stability, with the independent halves easily detaching, leading to unstable arcs, poor weld formation, and ultimately, difficulty in guaranteeing weld quality.

[0006] Chinese patent CN221560096U describes a method where flux sheets are sequentially fed into a spiral mold cylinder's limiting grooves to form a preliminary shape. Multiple flux sheets arranged in a strip are then bonded together into a flux strip by feeding adhesive ropes into the limiting grooves. The problem is that after the flux sheets enter the limiting grooves, they rely on an elastic clamping band to fix their position. However, this clamping action easily causes the flux sheets to shift within the limiting grooves, resulting in poor consistency in the spacing of the flux strip and directly affecting the stability of subsequent welding processes. Furthermore, during the adhesive rope bonding process, the positioning accuracy of the three adhesive ropes is difficult to guarantee, often resulting in the ropes not completely falling into their corresponding grooves, leading to insufficient bonding strength. During the subsequent ribbon feeding process, the flux sheets are prone to detachment due to bonding failure, causing problems such as unstable arc during welding and fluctuations in weld formation quality, thus restricting the reliability and efficiency of ultra-narrow gap welding.

[0007] No effective solutions have yet been proposed to address the problems in the relevant technologies. Utility Model Content

[0008] In view of the problems in related technologies, this utility model proposes a flux strip preparation device for ultra-narrow gap welding to overcome the above-mentioned technical problems existing in the existing related technologies.

[0009] To solve the above-mentioned technical problems, this utility model is achieved through the following technical solution: This utility model relates to a flux strip preparation device for ultra-narrow gap welding, comprising a carrier frame on which a vibrating disc and a wire clamp are mounted, and further comprising: The mold cylinder has at least one spiral limiting groove on its circumferential surface; The flux sheet conveying guide rail has one end fixed to the output rail of the vibratory feeder and fits into the output rail of the vibratory feeder so that the flux sheet slides from the output rail of the vibratory feeder onto the flux sheet conveying guide rail. The other end is connected to a spiral limiting groove so that the flux sheet slides from the flux sheet conveying guide rail into the spiral limiting groove. The limiting assembly includes a wire hoop and a fiberglass filler rope wound on it, the fiberglass filler rope being released from the wire hoop and entering the notch at the top of the flux sheet in the spiral limiting groove; The dispensing mechanism includes a dispensing machine fixed on a carrier and a dispensing pen connected to the dispensing machine, for intermittently dispensing flux sheets into a spiral limiting groove to bond the fiberglass filling rope and the flux sheets together. A transmission mechanism is mounted on a support frame, which is fixed to a carrier frame. The transmission mechanism is connected to the mold cylinder to drive the mold cylinder to rotate and move axially.

[0010] Furthermore, the transmission mechanism includes an internal thread seat, which is fixedly mounted on a support frame. The internal thread seat is threadedly connected to a screw. One end of the screw has a smooth surface and a guide groove is provided on it. A guide slider is slidably mounted on the guide groove. The guide slider is fixedly mounted on the inner surface of the drive ring. The middle part of the drive ring is rotatably mounted on the support frame. A large gear is fixedly mounted on one end of the drive ring. The large gear meshes with a small gear. The small gear is fixedly mounted on the output shaft of the motor. The other end of the screw is fixedly installed to the mold cylinder.

[0011] Furthermore, the flux sheet has an n-shaped structure, with a side wall thickness of 0.8-1.2 mm and an inner wall width of 1.2-1.5 mm.

[0012] Furthermore, the notch at the top of the flux sheet is 1 mm deep and 0.6 mm wide, matching the fiberglass filling cord.

[0013] Furthermore, the mold cylinder is a cylinder with open ends, with an outer diameter of 260mm and an inner diameter of 240mm.

[0014] Furthermore, the pitch of the spiral limiting groove is 3.5-4.5mm, the width is 3.3-3.7mm, and the depth is 4.5-5.5mm.

[0015] Furthermore, the flux sheet conveying guide rail is provided with an arc-shaped guide at the end near the mold cylinder. The radius of the arc-shaped guide is larger than the radius of the mold cylinder, so that the guide can approach and align with the spiral limiting groove on the outer periphery of the mold cylinder.

[0016] Furthermore, the dispensing machine is a peristaltic dispensing machine.

[0017] This utility model has the following beneficial effects: 1. This utility model utilizes a multi-ringed spiral limiting groove on the circumferential surface of the mold cylinder, enabling the mold cylinder and the front end of the transmission mechanism to rotate concentrically. This allows the mold cylinder to continuously form and accommodate long flux strips in a single operation. The transmission mechanism employs a mature screw drive, which offers high stability and ease of manufacturing. While the mold cylinder rotates, it can move along the screw axis, allowing the spiral limiting grooves to continuously and uninterruptedly form and accommodate long flux strips, effectively improving manufacturing efficiency and product length.

[0018] 2. This utility model achieves the sequential arrangement of flux sheets in the early stage by rotating the mold cylinder, and also constrains the flux sheets in the later stage with the glass fiber filling rope to form the flux strip prototype. This effectively prevents the flux strip in the spiral limiting groove from falling off when the mold cylinder rotates, and ensures the stability of the flux strip in the rotation strip making and subsequent dispensing process.

[0019] 3. This invention utilizes a dispensing pen positioned on the side of the mold cylinder. This allows the mold cylinder, fiberglass filling rope, and dispensing pen to work together to precisely apply adhesive to the flux strip pre-form, which has already been positioned within the spiral limiting groove of the mold cylinder. This ensures accurate distribution of adhesive at the connection point between the flux sheet and the fiberglass filling rope, achieving a strong bond. The dispensing pen operates intermittently according to the rotation rhythm of the mold cylinder, coordinating with the constraint and compression of the fiberglass filling rope to ensure a stable and continuous dispensing process. Before the adhesive cures, the flux sheet has formed a continuous strip structure within the limiting groove, initially possessing overall strength and transfer adaptability, ultimately forming a high-performance flux strip. This significantly improves the automation and efficiency of flux strip preparation.

[0020] Of course, any product implementing this utility model does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the utility model embodiments, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is one of the three-dimensional structural diagrams of this utility model; Figure 2 This is the second three-dimensional structural diagram of the present utility model; Figure 3 This is one of the partial structural diagrams of this utility model; Figure 4 This is the second partial structural diagram of the present invention.

[0023] The attached diagram lists the components represented by each number as follows: 1. Flux sheet; 2. Transmission mechanism; 201. Internal thread seat; 202. Screw; 203. Guide groove; 204. Drive ring; 205. Large gear; 206. Small gear; 207. Motor; 3. Support frame; 4. Mold cylinder; 5. Flux sheet conveying guide rail; 6. Wire clamp; 7. Fiberglass filling rope; 8. Dispensing pen; 9. Dispensing machine; 10. Vibrating plate; 11. Spiral limiting groove. Detailed Implementation

[0024] The technical solutions of the utility model embodiments will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the utility model, and not all embodiments. Based on the embodiments of the utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the utility model.

[0025] In the description of this utility model, it should be understood that the terms "opening", "upper", "lower", "top", "middle", "inner", etc., which indicate orientation or positional relationship, are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the utility model.

[0026] Please see Figures 1-4 As shown, this utility model is a flux strip preparation device for ultra-narrow gap welding, including a vibratory plate 10 and a wire clamp 6 mounted on a carrier, and also includes: The mold cylinder 4 has at least one spiral limiting groove 11 on its circumferential surface; The flux sheet conveying guide rail 5 has one end fixed to the output rail of the vibrating plate 10 and fits with the output rail of the vibrating plate 10 so that the flux sheet 1 slides from the output rail of the vibrating plate 10 onto the flux sheet conveying guide rail 5. The other end is connected to the spiral limiting groove 11 so that the flux sheet 1 slides from the flux sheet conveying guide rail 5 into the spiral limiting groove 11. The limiting component includes a wire clamp 6 and a glass fiber filling rope 7 wound on it. The glass fiber filling rope 7 is released from the wire clamp 6 and enters the top notch of the flux sheet 1 in the spiral limiting groove 11. As the mold cylinder 4 rotates, the wire clamp 6 continuously feeds the glass fiber filling rope 7 to the top notch of the flux sheet 1 that has entered the limiting groove, thereby pressing and fixing the multiple flux sheets 1 arranged in strips to prevent them from falling off when the mold cylinder 4 rotates. The dispensing mechanism includes a dispensing machine 9 fixed on a carrier and a dispensing pen 8 connected to the dispensing machine 9. It is used to intermittently dispense the flux sheet 1 into the spiral limiting groove 11 so that the glass fiber filling rope 7 and the flux sheet are bonded together. When the glass fiber filling rope 7 fixes the flux sheet 1 in the spiral limiting groove 11 of the mold cylinder 4 to form a strip-shaped prototype, the dispensing pen 8 uses the dispensing machine 9 to intermittently extrude the adhesive and precisely dispense it on the top of a single flux sheet 1, thereby firmly bonding multiple flux sheets 1 to the glass fiber filling rope 7 to form the final flux strip.

[0027] The dispensing pen 8 and the dispensing machine 9 are connected by a hose. The peristaltic pump inside the dispensing machine 9 drives the roller through the motor to squeeze the elastic hose in sequence. When the hose is squeezed, the internal volume of the hose changes and generates negative pressure, which draws the glue from the glue tube. After the roller rotates, the hose springs back and pushes the glue forward to the dispensing pen 8.

[0028] The transmission mechanism 2 is mounted on the support frame 3, which is fixed on the carrier frame. The transmission mechanism 2 is connected to the mold cylinder 4 to drive the mold cylinder 4 to rotate and move axially.

[0029] In one embodiment, the transmission mechanism 2 includes an internal thread seat 201, which is fixedly mounted on a support frame 3. The internal thread seat 201 is threadedly connected to a screw 202. One end of the screw 202 has a smooth surface and a guide groove 203 is provided thereon. A guide slider is slidably mounted on the guide groove 203. The guide slider is fixedly mounted on the inner surface of a drive ring 204. The middle part of the drive ring 204 is rotatably mounted on the support frame 3. A large gear 205 is fixedly mounted on one end of the drive ring 204. The large gear 205 meshes with a small gear 206. The small gear 206 is fixedly mounted on the output shaft of a motor 207. The other end of the screw 202 is fixedly installed with the mold cylinder 4.

[0030] The installation methods of screw 202 and mold cylinder 4 are as follows: A chuck is provided on the inner side of the mold cylinder 4. An inner groove is provided on one side of the chuck. A positioning plate is fixed through and fixed at one end of the screw 202. The positioning plate is adapted to the inner groove. When the positioning plate is adapted to the inner groove, the mold cylinder 4 and the screw 202 are coaxial. The screw 202 passes through the inner groove and the chuck. A fastening thread is provided on the surface of the end of the screw 202 that passes through the inner groove and the chuck to install a nut. The chuck and the positioning plate are fixed relative to each other by friction, thereby realizing the concentric rotation of the mold cylinder 4 and the screw 202.

[0031] The motor 207 drives the pinion 206 to rotate, which in turn drives the meshing gear 205 to rotate, thereby causing the drive ring 204 to rotate synchronously. The guide slider on the inner surface of the drive ring 204 cooperates with the guide groove 203 on the screw 202, thereby causing the drive ring 204 to drive the screw 202 to rotate. The screw 202 is threadedly connected to the internal thread seat 201 fixed on the support frame 3, so that the screw 202 rotates and moves axially at the same time, thereby causing the mold cylinder 4 to move smoothly along its axis while rotating, so that the spiral limiting groove 11 is continuously formed and can accommodate a long flux strip. This ensures that the rotational movement and axial feed of the mold cylinder 4 are precisely synchronized, and that the spiral limiting groove 11 on its surface can move forward continuously and stably. This not only realizes the orderly arrangement and spacing control of the flux sheet 1 in the groove, but also provides a stable forming foundation for the introduction and dispensing of the glass fiber filling rope 7, thereby effectively ensuring the continuity, consistency and overall structural stability of the flux strip preparation, and improving production efficiency and the product quality of the flux strip.

[0032] In one embodiment, the flux sheet 1 has an n-shaped structure, with a side wall thickness of 0.8-1.2 mm and an inner wall width of 1.2-1.5 mm.

[0033] Preferably, the thickness of the two side walls is 1 mm, and the width of the inner side wall is 1.3 mm. This ensures sufficient structural strength and appropriate arc confinement space.

[0034] In one embodiment, for the flux sheet 1, the depth of the notch at the top of the flux sheet 1 is 1 mm and the width is 0.6 mm, which matches the glass fiber filling rope 7, ensuring the reliability of the fixation.

[0035] In one embodiment, the mold cylinder 4 is a cylinder with open ends, with an outer diameter of 260 mm and an inner diameter of 240 mm.

[0036] In one embodiment, for the spiral limiting groove 11 described above, the pitch of the spiral limiting groove 11 is 3.5-4.5mm, preferably 4mm, the width is 3.3-3.7mm, preferably 3.5mm, and the depth is 4.5-5.5mm, preferably 5mm.

[0037] This ensures that the flux sheet slides down smoothly and accurately and is embedded in the spiral limiting groove, while preventing it from rolling or shifting within the groove, thus achieving excellent limiting effect and spacing consistency.

[0038] In one embodiment, for the flux sheet conveying guide rail 5, the end of the flux sheet conveying guide rail 5 near the mold cylinder 4 is provided with an arc-shaped guide portion. The radius of the arc-shaped guide portion is larger than the radius of the mold cylinder 4, so that the guide portion can approach and align with the spiral limiting groove 11 on the outer periphery of the mold cylinder 4. Thus, under the action of gravity, multiple flux sheets 1 arranged sequentially on the flux sheet conveying guide rail 5 can slide down along the flux sheet conveying guide rail 5 and be accurately guided into the spiral limiting groove 11.

[0039] Furthermore, dispensing machine 9 is a peristaltic dispensing machine.

[0040] Through the above technical solution, 1. By opening multiple spiral limiting grooves 11 on the circumferential surface of the mold cylinder 4, and making the mold cylinder 4 and the front end of the transmission mechanism 2 rotate concentrically, the mold cylinder 4 can be continuously formed in one go and accommodate a long flux strip. The transmission mechanism adopts a mature screw drive, which is highly stable and easy to manufacture. This allows the mold cylinder 4 to move axially along the screw 202 while rotating, enabling the spiral limiting groove 11 to continuously and uninterruptedly form and accommodate longer flux strips, effectively improving manufacturing efficiency and product length. Secondly, the rotation of the mold cylinder 4 not only achieves the sequential arrangement of flux sheets 1 in the early stage but also, in conjunction with the subsequent constraint of the glass fiber filling rope 7 on the flux sheets 1, forms a preliminary flux strip shape. This effectively prevents the flux strip from falling off the spiral limiting groove 11 during the rotation of the mold cylinder 4, ensuring the stability of the flux strip during rotational strip forming and subsequent dispensing. Thirdly, a dispensing pen 8 is set on the side of the mold cylinder 4, allowing the mold cylinder 4, glass fiber filling rope 7, and dispensing pen 8 to work together to precisely apply adhesive to the preliminary flux strip shape already positioned within the spiral limiting groove 11 of the mold cylinder 4. This ensures that the adhesive is precisely distributed at the connection between the flux sheets 1 and the glass fiber filling rope 7, achieving a strong bond. The dispensing pen 8 operates intermittently according to the rotation rhythm of the mold cylinder 4, and is constrained and pressed by the glass fiber filling rope 7, ensuring the stability and continuity of the dispensing process. Before the adhesive cures, the flux sheet 1 has formed a continuous strip structure in the limiting groove, initially possessing overall strength and transfer adaptability, and finally forming a high-performance flux strip, which significantly improves the automation and preparation efficiency of flux strip preparation.

[0041] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0042] The preferred embodiments of the utility model disclosed above are merely illustrative of the utility model. These preferred embodiments do not exhaustively describe all details, nor do they limit the utility model to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the utility model, thereby enabling those skilled in the art to better understand and utilize it. The utility model is limited only by the claims and their full scope and equivalents.

Claims

1. A flux strip preparation apparatus for ultra-narrow gap welding, comprising a carrier frame on which a vibrating disc and a wire clamp are mounted, characterized in that, Also includes: The mold cylinder has at least one spiral limiting groove on its circumferential surface; The flux sheet conveying guide rail has one end fixed to the output rail of the vibratory feeder and fits into the output rail of the vibratory feeder so that the flux sheet slides from the output rail of the vibratory feeder to the flux sheet conveying guide rail. The other end is connected to the spiral limiting groove so that the flux sheet slides from the flux sheet conveying guide rail into the spiral limiting groove. The limiting assembly includes a wire hoop and a fiberglass filler rope wound on it, the fiberglass filler rope being released from the wire hoop and entering the notch at the top of the flux sheet in the spiral limiting groove; The dispensing mechanism includes a dispensing machine fixed on a carrier and a dispensing pen connected to the dispensing machine, for intermittently dispensing flux sheets into a spiral limiting groove to bond the fiberglass filling rope and the flux sheets together. The transmission mechanism is mounted on the support frame, which is fixed to the carrier frame. The transmission mechanism is connected to the mold cylinder to drive the mold cylinder to rotate and move axially.

2. The flux strip preparation device for ultra-narrow gap welding according to claim 1, characterized in that, The transmission mechanism includes an internal thread seat, which is fixedly mounted on a support frame. The internal thread seat is threadedly connected to a screw. One end of the screw has a smooth surface and a guide groove is provided on it. A guide slider is slidably mounted on the guide groove. The guide slider is fixedly mounted on the inner surface of the drive ring. The middle part of the drive ring is rotatably mounted on the support frame. A large gear is fixedly mounted on one end of the drive ring. The large gear meshes with a small gear. The small gear is fixedly mounted on the output shaft of the motor. The other end of the screw is fixedly installed to the mold cylinder.

3. The flux strip preparation device for ultra-narrow gap welding according to claim 2, characterized in that, The flux sheet has an n-shaped structure, with a side wall thickness of 0.8-1.2 mm and an inner wall width of 1.2-1.5 mm.

4. The flux strip preparation device for ultra-narrow gap welding according to claim 3, characterized in that, The flux sheet has a 1mm deep and 0.6mm wide notch at the top, which matches the fiberglass filling cord.

5. The flux strip preparation device for ultra-narrow gap welding according to claim 4, characterized in that, The mold cylinder is a cylinder with open ends, with an outer diameter of 260mm and an inner diameter of 240mm.

6. The flux strip preparation device for ultra-narrow gap welding according to claim 5, characterized in that, The pitch of the spiral limiting groove is 3.5-4.5mm, the width is 3.3-3.7mm, and the depth is 4.5-5.5mm.

7. The flux strip preparation apparatus for ultra-narrow gap welding according to claim 6, characterized in that, The flux sheet conveying guide rail has an arc-shaped guide section at the end near the mold cylinder. The radius of the arc-shaped guide section is larger than the radius of the mold cylinder, so that the guide section can approach and align with the spiral limiting groove on the outer circumference of the mold cylinder.

8. The flux strip preparation apparatus for ultra-narrow gap welding according to claim 7, characterized in that, The dispensing machine is a peristaltic dispensing machine.

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