A welding device for heat exchanger processing

Abstract

This utility model discloses a welding device for heat exchanger processing, belonging to the field of machining technology. The device includes a T-shaped support, a centering and positioning mechanism, a left limiting rotation mechanism, and a right limiting rotation mechanism. The centering and positioning mechanism drives a rotating rod to rotate via a drive motor, causing the left and right sleeves to move in opposite directions, thus achieving centering and positioning of the two heat exchanger tubes. The left and right limiting rotation mechanisms use cylinders to drive the upper and lower V-blocks to clamp the tubes, and a servo reduction motor drives the active roller to rotate, thereby rotating the tubes and facilitating welding of the butt joint. This utility model improves centering accuracy and welding quality, achieves automatic rotation of the tubes, reduces labor intensity, improves operational safety, and is suitable for tubes of different diameters, making it highly practical.

Description

Technical Field

[0001] This utility model belongs to the field of mechanical processing technology, specifically relating to a device for welding pipe fittings in the process of heat exchanger manufacturing, and more particularly to a welding device for heat exchanger processing. Background Technology

[0002] Heat exchangers, as key equipment for achieving heat exchange, are widely used in many industrial fields such as petroleum, chemical, power, and metallurgy. The core components of a heat exchanger are various pipe fittings, and the quality of the connections between these fittings, especially the welding quality, directly determines the heat exchanger's heat exchange efficiency, sealing performance, and service life.

[0003] In the manufacturing process of heat exchangers, the welding of tubes is a crucial step. Currently, traditional methods for welding heat exchanger tubes have many drawbacks. When butt-welding two sections of heat exchanger tubes, manual positioning is usually required. This not only consumes a significant amount of manpower and time, resulting in low efficiency, but also makes it difficult to guarantee the accuracy of manual alignment. This can easily lead to misalignment, uneven gaps, and other problems at the weld joint, severely affecting the weld quality and consequently reducing the performance of the heat exchanger.

[0004] Furthermore, during the welding process, the joint between the two pipe sections needs to be welded around the entire circumference. Traditionally, after welding at a certain angle, the pipe is manually rotated to change the welding position. This method not only increases the labor intensity of the operators but also easily causes displacement of the pipe during rotation, compromising existing alignment accuracy and affecting subsequent welding quality. Additionally, manual operation near the welding area poses safety hazards such as burns from high-temperature welding slag.

[0005] Therefore, in order to solve the problems of low centering and positioning accuracy, low efficiency, inconvenient welding operation and poor safety in the existing heat exchanger tube welding process, it is of great practical significance to develop a welding device that can realize automatic centering and positioning and automatic rotation of tubes. Utility Model Content

[0006] This invention aims to solve the problems of low centering accuracy and low efficiency in the existing heat exchanger tube welding process, as well as the inconvenience and safety hazards of manually rotating the tubes when welding a circle of butt joints.

[0007] A welding device for heat exchanger processing includes a pair of T-shaped supports, with a centering and positioning mechanism provided on the top of the pair of T-shaped supports, and a left limit rotation mechanism and a right limit rotation mechanism provided on the centering and positioning mechanism.

[0008] Furthermore, the centering and positioning mechanism includes a U-shaped support fixed on a pair of T-shaped supports. A rotating rod is provided on the U-shaped support, and the two ends of the rotating rod are provided with external threads in opposite directions. A left sleeve and a right sleeve are respectively threaded onto the opposite external threads. A protective cover is provided on the U-shaped support. A pair of guide holes are provided on the front and rear side walls of the protective cover. A left bracket and a right bracket are provided through the guide holes on the front and rear side walls of the left and right sleeves. The left bracket and the right bracket are respectively fixedly connected to the left limiting rotation mechanism and the right limiting rotation mechanism.

[0009] Furthermore, the left and right limit rotation mechanisms are identical in size and symmetrically arranged. The left limit rotation mechanism includes a rectangular frame fixed on the left support. A lower V-shaped block is fixed at the bottom inside the rectangular frame. An active roller and an auxiliary roller are movably arranged on the two side walls of the lower V-shaped block, respectively. A servo reduction motor with an output shaft connected to the active roller is arranged on the V-shaped block. A cylinder is fixed at the top of the rectangular frame. The piston rod of the cylinder passes through the rectangular frame and is arranged on an upper V-shaped block. Upper auxiliary rollers are arranged on the two side walls of the upper V-shaped block.

[0010] Furthermore, a drive motor with an output shaft connected to one end of a rotating rod is fixed on the U-shaped support, and the other end of the rotating rod is rotatably connected to the inner wall of the U-shaped support through a bearing.

[0011] Furthermore, the protective cover is made of welded steel plate, and the protective cover is detachably fixed to the U-shaped support by bolts.

[0012] Furthermore, the outer circumferential surfaces of the active roller, auxiliary roller, and upper auxiliary roller are all covered with a wear-resistant rubber layer, and the surface of the rubber layer is provided with anti-slip texture.

[0013] Furthermore, the V-groove angles of both the lower V-block and the upper V-block are 90 degrees, and the lower V-block is connected to the rectangular frame by welding, while the upper V-block is connected to the cylinder piston rod by threaded connection.

[0014] Furthermore, guide sliders are fixed on the side of the left and right brackets near the guide hole, and guide grooves that cooperate with the guide sliders are provided on the inner wall of the protective cover.

[0015] Compared with the prior art, the beneficial effects of this utility model are:

[0016] Improved alignment accuracy: The alignment and positioning mechanism enables automatic alignment and positioning of the two heat exchanger tubes, which greatly improves alignment accuracy and ensures welding quality compared to manual positioning.

[0017] Automatic rotation is achieved: the left and right limit rotation mechanisms can drive the pipe to rotate automatically without manual rotation. This not only reduces the labor intensity of operators, but also avoids pipe displacement that may occur during manual rotation, ensuring the continuity and stability of welding, and improving welding efficiency and quality.

[0018] Wide range of applications: The V-groove design of the upper and lower V-blocks can accommodate circular pipes of different diameters, expanding the applicability of the device. Attached Figure Description

[0019] 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:

[0020] Figure 1 This is a schematic diagram of the structure of this utility model;

[0021] Figure 2 This is a partial cross-sectional view of the centering and positioning mechanism of this utility model;

[0022] Figure 3 This is a schematic diagram of the left limit rotation mechanism of this utility model;

[0023] Figure 4 This is a schematic diagram of the lower V-shaped block structure of this utility model;

[0024] In the picture:

[0025] 1. T-shaped support; 2. Centering and positioning mechanism; 21. U-shaped support; 22. Rotating rod; 23. Left sleeve; 24. Right sleeve; 25. Protective cover; 26. Guide hole; 27. Left bracket; 28. Right bracket; 3. Left limit rotation mechanism; 31. Rectangular frame; 32. Lower V-block; 33. Active roller; 34. Auxiliary roller; 35. Servo geared motor; 36. Cylinder; 37. Upper V-block; 38. Upper auxiliary roller; 4. Right limit rotation mechanism. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] Example 1

[0028] like Figure 1-4 As shown;

[0029] A welding device for heat exchanger processing.

[0030] This implementation plan aims to address the technical problems existing in the prior art, such as the background art disclosed above, which states that "heat exchangers, as key equipment for achieving heat exchange, are widely used in many industrial fields such as petroleum, chemical, power, and metallurgy. The core components of a heat exchanger are various pipe fittings, and the connection quality between these pipe fittings, especially the welding quality, directly determines the heat exchange efficiency, sealing performance, and service life of the heat exchanger."

[0031] In the manufacturing process of heat exchangers, the welding of tubes is a crucial step. Currently, traditional methods for welding heat exchanger tubes have many drawbacks. When butt-welding two sections of heat exchanger tubes, manual positioning is usually required. This not only consumes a significant amount of manpower and time, resulting in low efficiency, but also makes it difficult to guarantee the accuracy of manual alignment. This can easily lead to misalignment, uneven gaps, and other problems at the weld joint, severely affecting the weld quality and consequently reducing the performance of the heat exchanger.

[0032] Furthermore, during the welding process, the joint between the two pipe sections needs to be welded around the entire circumference. Traditionally, after welding at a certain angle, the pipe is manually rotated to change the welding position. This method not only increases the labor intensity of the operators but also easily causes displacement of the pipe during rotation, compromising existing alignment accuracy and affecting subsequent welding quality. Simultaneously, manual operation near the welding area poses safety hazards such as burns from high-temperature welding slag. Considering practical application, this problem is clearly a real and difficult-to-solve issue. Therefore, to address this technical problem, a welding device for heat exchanger processing is provided.

[0033] like Figure 1-4 As shown in the figure;

[0034] This utility model provides a technical solution: including a pair of T-shaped supports 1, with a centering and positioning mechanism 2 fixed to the top of the pair of T-shaped supports 1 by bolts, and a left limit rotation mechanism 3 and a right limit rotation mechanism 4 provided on the centering and positioning mechanism 2.

[0035] The centering and positioning mechanism 2 includes a U-shaped support 21 fixed to a pair of T-shaped supports 1 by bolts. A rotating rod 22 is provided on the U-shaped support 21. A drive motor with an output shaft connected to one end of the rotating rod 22 is fixed to the U-shaped support 21 by bolts. The other end of the rotating rod 22 is rotatably connected to the inner wall of the U-shaped support 21 through a bearing. The rotating rod 22 has external threads with opposite directions at both ends. A left sleeve 23 and a right sleeve 24 are threaded onto the opposite external threads, respectively. A protective cover 25 made of welded steel plate is detachably fixed to the U-shaped support 21 by bolts. A pair of guide holes 26 are opened on the front and rear side walls of the protective cover 25. A left bracket 27 and a right bracket 28 are set through the guide holes 26 on the front and rear side walls of the left sleeve 23 and the right sleeve 24. A guide slider is fixed on the side of the left bracket 27 and the right bracket 28 near the guide hole 26. A guide groove is opened on the inner side wall of the protective cover 25 to cooperate with the guide slider. The left bracket 27 and the right bracket 28 are welded and fixed to the left limit rotation mechanism 3 and the right limit rotation mechanism 4, respectively.

[0036] The left limit rotation mechanism 3 and the right limit rotation mechanism 4 are the same size and are symmetrically arranged. The left limit rotation mechanism 3 includes a rectangular frame 31 welded and fixed to the left bracket 27. A lower V-shaped block 32 is welded and fixed to the bottom of the rectangular frame 31. The two side walls of the lower V-shaped block 32 are respectively movably arranged with an active roller 33 and an auxiliary roller 34 through bearings. A servo reduction motor 35 with an output shaft connected to the active roller 33 is fixed to the V-shaped block 32 by bolts. A cylinder 36 is fixed to the top of the rectangular frame 31 by bolts. An upper V-shaped block 37 is arranged through the rectangular frame 31 with the piston rod of the cylinder 36. The upper V-shaped block 37 is connected to the piston rod of the cylinder 36 by a threaded connection. The two side walls of the upper V-shaped block 37 are arranged with upper auxiliary rollers 38 through bearings. The V-groove angles of the lower V-block 32 and the upper V-block 37 are both 90 degrees. The outer circumference of the active roller 33, the auxiliary roller 34 and the upper auxiliary roller 38 are all covered with a wear-resistant rubber layer, and the surface of the rubber layer is provided with anti-slip texture.

[0037] Loading and initial placement: Place the two heat exchanger tube sections to be welded onto the lower V-blocks of the left and right limit rotation mechanisms, respectively, so that the mating ends of the two tube sections are facing each other. The V-groove of the lower V-block provides initial positioning and support for the tube sections, and the active roller and auxiliary roller are in contact with the outer circumferential surface of the tube sections.

[0038] Clamping the pipe fittings: Activate the cylinders in the left and right limit rotation mechanisms. The piston rods of the cylinders extend downwards, causing the upper V-block to move downwards until the upper auxiliary roller on the upper V-block makes tight contact with the outer circumference of the pipe fitting, firmly clamping the two heat exchanger tubes between the lower and upper V-blocks respectively. The V-groove angles of both the upper and lower V-blocks are 90 degrees, which can accommodate circular pipe fittings of different diameters and ensure clamping stability.

[0039] Centering and Positioning: The drive motor in the centering and positioning mechanism is activated, causing the rotating rod to rotate. Since the threads at both ends of the rotating rod are in opposite directions, and the left and right sleeves are connected to the opposite threads on the rotating rod, the left and right sleeves move in opposite directions along the rotating rod as it rotates. The left sleeve moves the left limiting rotation mechanism via the left support, and the right sleeve moves the right limiting rotation mechanism via the right support, thereby gradually bringing the mating ends of the two clamped heat exchanger tubes closer together and accurately centering them. During the movement of the left and right supports, the guide sliders on their sidewalls slide within the guide grooves on the inner sidewall of the protective cover, providing guidance and ensuring smooth movement and centering accuracy. The protective cover prevents external debris from entering the centering and positioning mechanism and affecting its normal operation.

[0040] Rotation during welding: After alignment, welding can begin. During welding, the servo reduction motors in the left and right limit rotation mechanisms are activated, and their output shafts drive the active roller to rotate. Because the active roller is in close contact with the outer circumference of the pipe fitting, and the outer circumferences of the active roller, auxiliary roller, and upper auxiliary roller are all covered with a wear-resistant rubber layer with anti-slip texture, the friction between them and the pipe fitting is increased. When the active roller rotates, the friction causes the pipe fitting to rotate synchronously. The auxiliary roller and upper auxiliary roller provide support and guidance during pipe fitting rotation, ensuring smooth rotation and preventing wobbling. This ensures the stability of the welding process and facilitates continuous and uniform welding of the butt joint between the two pipe sections.

[0041] Welding Completion and Unloading: After welding is completed, the servo reduction motor is turned off, stopping the rotation of the pipe. The piston rod of the control cylinder retracts upward, causing the upper V-block to move upward and loosen the clamp on the pipe. Then, the drive motor is started, causing the rotating rod to rotate in the opposite direction. The left and right limit rotation mechanisms move in opposite directions, removing the welded pipe.

[0042] Finally, it should be noted that the above are merely preferred embodiments of this utility model and are 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 welding device for heat exchanger processing, comprising a pair of T-shaped supports (1), characterized in that: A centering and positioning mechanism (2) is provided on the top of a pair of T-shaped supports (1). The centering and positioning mechanism (2) is provided with a left limiting rotation mechanism (3) and a right limiting rotation mechanism (4). The centering and positioning mechanism (2) includes a U-shaped support (21) fixed on a pair of T-shaped supports (1). A rotating rod (22) is provided on the U-shaped support (21). The rotating rod (22) has external threads with opposite thread directions at both ends. A left sleeve (23) and a right sleeve (24) are threaded onto the opposite external threads, respectively. A protective cover (25) is provided on the U-shaped support (21). A pair of guide holes (26) are provided on the front and rear side walls of the protective cover (25). A left bracket (27) and a right bracket (28) are provided through the guide holes (26) on the front and rear side walls of the left sleeve (23) and the right sleeve (24). The left bracket (27) and the right bracket (28) The left and right limit rotation mechanisms are fixedly connected to the left limit rotation mechanism (3) and the right limit rotation mechanism (4) respectively. The left limit rotation mechanism (3) and the right limit rotation mechanism (4) are the same size and are symmetrically arranged. The left limit rotation mechanism (3) includes a rectangular frame (31) fixed on the left support (27). A lower V-shaped block (32) is fixed at the bottom inside the rectangular frame (31). An active roller (33) and an auxiliary roller (34) are movably arranged on the two side walls of the lower V-shaped block (32). A servo reduction motor (35) with an output shaft connected to the active roller (33) is arranged on the V-shaped block (32). A cylinder (36) is fixed at the top of the rectangular frame (31). An upper V-shaped block (37) is arranged through the rectangular frame (31). An upper auxiliary roller (38) is arranged on the two side walls of the upper V-shaped block (37).

2. The welding apparatus for processing a heat exchanger according to claim 1, characterized in that: A drive motor with an output shaft connected to one end of a rotating rod (22) is fixed on the U-shaped support (21). The other end of the rotating rod (22) is rotatably connected to the inner wall of the U-shaped support (21) through a bearing.

3. The welding apparatus for processing a heat exchanger according to claim 1, characterized in that: The protective cover (25) is made of welded steel plate and is detachably fixed to the U-shaped support (21) by bolts.

4. The welding apparatus for processing a heat exchanger according to claim 1, characterized in that: The outer circumferential surfaces of the active roller (33), auxiliary roller (34) and upper auxiliary roller (38) are all covered with a wear-resistant rubber layer, and the surface of the rubber layer is provided with anti-slip texture.

5. The welding apparatus for processing a heat exchanger according to claim 1, characterized in that: The V-groove angles of the lower V-block (32) and the upper V-block (37) are both 90 degrees. The lower V-block (32) is connected to the rectangular frame (31) by welding, and the upper V-block (37) is connected to the piston rod of the cylinder (36) by threaded connection.

6. The welding apparatus for processing a heat exchanger according to claim 1, characterized in that: The left bracket (27) and the right bracket (28) are both fixed with guide sliders on the side near the guide hole (26), and the inner wall of the protective cover (25) is provided with guide grooves that cooperate with the guide sliders.

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