Heavy-duty gear welding device

Abstract

This application discloses a heavy-duty gear welding device. A horizontal arm is adjustable in position along the length of the base and mounted on a vertical slide. A welding wire spool is located at the rear end of the horizontal arm. A transverse drive unit is mounted at the front end of the horizontal arm. A worktable is mounted at the output end of the transverse drive unit and driven along the length of the horizontal arm. The heavy-duty gear welding device provided by this utility model includes a gear mounting part comprising a rotating motor and a horizontally positioned chuck driven by the rotating motor. The horizontal arm is adjustable in position along the length of the base and mounted on a vertical slide. A welding wire spool is located at the rear end of the horizontal arm. The worktable is mounted at the output end of the transverse drive unit and driven along the length of the horizontal arm. The horizontal arm's position is adjusted in two stages. The horizontal arm itself is adjustable on the vertical slide, and with the assistance of the transverse drive unit, the worktable's position is easily adjustable. When not in use, the worktable is retracted towards the horizontal arm via the transverse drive unit, reducing space occupation and the possibility of structural deformation at the worktable end.

Description

Technical Field

[0001] This utility model relates to the field of welding equipment, and in particular to a heavy-duty gear welding device. Background Technology

[0002] Major equipment in the petroleum, petrochemical, and coal mining machinery industries is becoming increasingly large, leading to increased demand for heavy-duty gears. The high restraint of heavy-duty thick-walled structures and the large filler volume of traditional welding processes bring about many problems, such as low production efficiency, high welding heat input, and large residual stress and deformation in the welded joint, which causes significant damage to the joint's plasticity and toughness, resulting in poor mechanical properties of the welded joint.

[0003] Narrow gap welding technology retains the advantages of traditional welding methods while ideally overcoming the aforementioned limitations. Compared with traditional welding techniques, it significantly reduces the weld cross-sectional area, saves filler material, and lowers the total welding heat input of the joint, thereby increasing welding productivity and reducing welding production costs. In particular, due to the smaller filler material and lower total heat input, it not only results in lower residual stress and residual deformation in the joint and a finer weld microstructure, but also greatly reduces ductile and toughness damage to the joint, making it easier to obtain high-precision, high-performance joints. Therefore, narrow gap welding technology has become an important welding forming and manufacturing technology for thick-walled structures of heavy equipment in the petroleum, petrochemical, and coal mining machinery industries.

[0004] Narrow gap welding is the preferred welding process for thick-walled structures, and it has many technical and economic advantages compared to traditional multi-layer, multi-pass, large-groove welding.

[0005] 1) Energy saving, material saving, and high efficiency: Due to the significant reduction in groove gap and the reduction in filler weld metal, energy input is reduced, which greatly improves welding productivity and reduces production costs.

[0006] 2) Low welding heat input, stress deformation, and thermal damage: Low heat input results in lower welding residual stress and deformation in the joint, a smaller heat-affected zone, and less thermal damage to the base material.

[0007] 3) High weld quality: The uniformity of weld microstructure and properties is improved, and the mechanical properties, especially the ductility and toughness, are improved.

[0008] 4) Significant economic advantages in the field of thick plate welding: As the plate thickness increases, the material and labor costs saved by narrow gap welding become increasingly larger. Generally speaking, the production cost is reduced by at least 40% compared to traditional welding methods.

[0009] The equipment used in the narrow-gap welding process lacks consideration for heavy-duty gears, and has low automation and accuracy. Utility Model Content

[0010] The main objective of this invention is to provide a heavy-duty gear welding device, which aims to solve the problems of devices used in narrow-gap welding processes that lack consideration for heavy-duty gears and have low automation and accuracy.

[0011] To achieve the above objectives, this utility model provides a heavy-duty gear welding device, comprising: The base includes a base and a support column disposed at one end of the base along its length. A vertical drive unit is disposed on the support column, and the vertical drive unit drives a vertical slide seat in the vertical direction. A gear mounting part is installed at the other end of the base along its length. The gear mounting part includes a rotating motor and a horizontally arranged chuck driven by the rotating motor. A horizontal arm is installed on the vertical slide seat in an adjustable position along the length of the base. A welding wire reel is provided at the rear end of the horizontal arm, wherein the welding wire reel is used to install external welding wire. A lateral drive unit is installed at the front end of the cross arm; A worktable is installed at the output end of the transverse drive unit and driven over the length of the transverse arm. The worktable is vertically downwardly provided with a welding wire output unit and a fixing rod. The fixing rod is connected to the lower end of the welding wire output unit. The welding wire output unit drives and heat-melts the welding wire. The control center connects and controls the operation of the gear mounting section, the horizontal drive section, the vertical drive section, and the welding wire output section.

[0012] Furthermore, the cross arm includes a rear arm and a front arm telescopically disposed in the rear arm, and the lateral drive unit is disposed in the front arm.

[0013] Furthermore, the welding wire spool includes a spool base and a rotating wheel rotatably mounted on the spool base. A wire feeding arm is provided on the spool base, wherein the welding wire passes through the wire feeding arm from the rotating wheel and is then guided into the welding wire output section.

[0014] Furthermore, the fixed angle of the wire-exiting arm in the vertical plane is adjustable.

[0015] Furthermore, the end of the wire feeding arm is slidably and rotatably mounted on a roller in the thickness direction of the rotating wheel, and a wire spool for the welding wire to pass through is fixed on the roller, wherein the roller is parallel to the central axis of the rotating wheel.

[0016] Furthermore, the position of the welding wire spool is adjustable along the length of the cross arm.

[0017] Furthermore, the operation of the lateral drive unit is driven by a linear motor.

[0018] Furthermore, the extended path of the fixed rod moving in the horizontal direction passes through the center of the chuck.

[0019] Furthermore, the vertical drive unit operates hydraulically.

[0020] Furthermore, the vertical slide seat has a groove structure in the length direction of the base, the horizontal arm is slidably installed in the groove structure, and a locking structure is provided on the vertical slide seat corresponding to the horizontal arm.

[0021] The heavy-duty gear welding device provided by this utility model includes a gear mounting part comprising a rotating motor and a horizontally arranged chuck driven by the rotating motor. A horizontal arm is mounted on a vertical slide seat with an adjustable position along the length of the base. A welding wire spool is provided at the rear end of the horizontal arm. The worktable is mounted on the output end of the horizontal drive unit and is driven along the length of the horizontal arm. The position of the horizontal arm is adjusted in two stages. The position of the horizontal arm itself on the vertical slide seat is adjustable, and with the assistance of the horizontal drive unit, the position of the worktable is easily adjustable. When not in operation, the worktable can be retracted towards the horizontal arm by the horizontal drive unit, reducing the space occupied and the possibility of structural deformation at the end of the worktable. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the first perspective of the heavy-duty gear welding device according to the first embodiment of this utility model (the horizontal arm is not extended and the lateral drive part is not extended). Figure 2 This is a schematic diagram from the second perspective of the first embodiment of the heavy-duty gear welding device of this utility model (the horizontal arm is not extended and the lateral drive part is not extended). Figure 3 This is a schematic diagram of the cross arm in the heavy-duty gear welding device of the first embodiment of this utility model; Figure 4 yes Figure 3 A partial magnification; Figure 5 This is a schematic diagram of the first perspective of the heavy-duty gear welding device of the first embodiment of this utility model (horizontal arm extended, lateral drive part extended). Detailed Implementation

[0023] It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0024] Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” “the,” “the,” “the,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in this specification means the presence of the stated features, integers, steps, operations, elements, units, modules, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, units, modules, components, and / or groups thereof. It should be understood that when we say an element is “connected” or “coupled” to another element, it can be directly connected or coupled to the other element, or there may be intermediate elements. Furthermore, “connected” or “coupled” as used herein can include wireless connection or wireless coupling. The term “and / or” as used herein includes all or any units and all combinations of one or more associated listed items.

[0025] It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless specifically defined as herein.

[0026] Reference Figures 1 to 5 In one embodiment of this utility model, a heavy-duty gear welding device includes: The base portion 100 includes a base 110 and a support column 120 disposed at one end of the base 110 in the length direction. A vertical drive portion 130 is disposed on the support column 120, and the vertical drive portion 130 drives a vertical slide seat 131 in the vertical direction. A gear mounting part 200 is mounted at the other end of the base 110 along its length. The gear mounting part 200 includes a rotating motor and a horizontally arranged chuck 210 driven by the rotating motor. A horizontal arm 300 is installed on the vertical slide seat 131 in an adjustable position along the length of the base 110. A welding wire spool 310 is provided at the rear end of the horizontal arm 300, wherein the welding wire spool 310 is used to install external welding wire. A lateral drive unit 400 is installed at the front end of the cross arm 300; A worktable 500 is installed at the output end of the transverse drive unit 400 and driven along the length of the transverse arm 300. The worktable 500 is vertically downwardly provided with a welding wire output unit 510 and a fixing rod 520. The fixing rod 520 is connected to the lower end of the welding wire output unit 510. The welding wire output unit 510 drives and heat-melts the welding wire. The control center 600 connects and controls the operation of the gear mounting part 200, the horizontal drive part 400, the vertical drive part 130, and the welding wire output part 510.

[0027] In the existing technology, the equipment used for narrow gap welding processes lacks consideration for heavy-duty gears, and has low automation and accuracy.

[0028] The heavy-duty gear welding device provided by this utility model includes a base part 100, a gear mounting part 200, a cross arm 300, a transverse drive part 400, a worktable 500, and a control center 600.

[0029] The base portion 100 includes a base 110 and a support column 120 disposed at one end of the base 110 along its length. A vertical drive portion 130 is disposed on the support column 120, and the vertical drive portion 130 may operate by hydraulic, pneumatic, or electric motor, etc. The vertical drive portion 130 drives a vertical slide block 131 in the vertical direction.

[0030] The gear mounting part 200 is mounted at the other end of the base 110 along its length. The gear mounting part 200 includes a rotary motor and a horizontally positioned chuck 210 driven by the rotary motor. The rotary motor can drive the chuck 210 via a geared motor or the like. The structural form of the chuck 210 is based on various existing designs and is not the focus of this discussion.

[0031] The horizontal arm 300 is adjustablely mounted on the vertical slide block 131 along the length of the base 110. For example, a fixing groove is provided on the vertical slide block 131 corresponding to the horizontal arm 300 to restrict the sliding of the horizontal arm 300. A wire spool 310 is provided at the rear end of the horizontal arm 300. The wire spool 310 is used to hold external welding wire. The rotation of the wire spool 310 can complete the wire feeding. For example, the wire spool 310 includes a spool base 311 and a rotating wheel 312 rotatably mounted on the spool base 311. The welding wire is wound on the rotating wheel 312. When the welding wire is pulled out of the rotating wheel 312, the rotating wheel 312 rotates accordingly.

[0032] The lateral drive unit 400 is mounted on the front end of the cross arm 300 and is capable of performing linear drive in the horizontal direction.

[0033] The worktable 500 is mounted at the output end of the transverse drive unit 400 and driven along the length of the cross arm 300. The transverse drive unit 400 can operate hydraulically or via a linear motor, etc. The worktable 500 has a welding wire output unit 510 and a fixing rod 520 vertically downwards. The precise position adjustment of the cross arm 300 is automated by arranging the transverse drive unit 400 at the front end of the cross arm 300, which adjusts the position of the worktable 500. The cross arm 300 itself is adjustable on the vertical slide 131, and with the assistance of the transverse drive unit 400, the position adjustment of the worktable 500 is convenient. However, during operation, due to the large dimensional deviation of the gears, the adjustment position of the transverse drive unit 400 can easily accumulate dimensional errors, while also increasing the working pressure on the transverse drive unit 400. Coarse adjustments are achieved by adjusting the position of the cross arm 300 itself on the vertical slide 131, while precise adjustments are achieved by the operation of the transverse drive unit 400, thus facilitating the overall position adjustment of the worktable 500. A fixing rod 520 is connected to the lower end of the welding wire output section 510, thereby fixing the position of the welding wire output section 510. The welding wire output section 510 drives and heats the welding wire. For example, the welding wire output section 510 includes a wire feeding structure and an electric welding section. The wire feeding structure includes a wire feeding motor and two oppositely arranged wire feeding wheels. The wire feeding motor controls the rotation of the two wire feeding wheels. The welding wire passes through the two wire feeding wheels and is driven as the wire feeding wheels rotate relative to each other. The electric welding section provides welding current and is positioned corresponding to the welding wire, thereby enabling the end to be heat-melted.

[0034] The control center 600 connects and controls the operation of the gear mounting unit 200, the horizontal drive unit 400, the vertical drive unit 130, and the welding wire output unit 510.

[0035] During operation, the heavy-duty gear is installed on the chuck 210 of the gear mounting part 200. The vertical drive part 130 is controlled to drive the horizontal arm 300 to a suitable height. The horizontal arm 300 is manually moved to a suitable position on the vertical slide 131 and locked. The horizontal drive part 400 is controlled to move the worktable 500 to the welding position and start the welding process. The vertical drive part 130 is controlled to adjust the vertical position and the chuck 210 driven by the rotary motor is controlled to rotate.

[0036] In one implementation process, the workpiece was an 80 mm 42CrNiMo heavy-duty gear with a U-shaped bevel width of 10 mm and a depth of 84 mm; 32 layers were welded (total time 4.5 h), with a heat input ≤1.8 kJ / mm; post-weld UT inspection: defect rate <0.1%, hardness gradient ≤30 HV. No beveling design is required. A parallel welding zone with a width of 8-12mm is reserved between the gear base and the teeth, with a depth matching the gear thickness (50-300mm) and a sidewall inclination angle of ±1°. Ultrasonic testing confirms the absence of cracks. A single-wire welding torch is used, with φ1.0-1.2mm solid welding wire. A mixed gas is used, with a composition of 80%Ar + 18%CO2 + 2%O2 and a flow rate of 25-35L / min. The welding torch is equipped with a transverse oscillation mechanism with an oscillation amplitude of 5.0-10.0mm and a frequency of 1-3Hz. The welding wire is equipped with a mechanical bending device to make the welding wire form an S-shaped curve with a deflection amplitude of 5-10mm. The welding current for the root pass is 280-320A and the voltage is 28-30V. The welding current for the fill pass is 320-360A and the voltage is 30-32V. The welding current for the cap pass is 260-300A and the voltage is 26-28V. Compared with traditional narrow-gap welding using heavy-duty gear welding equipment, the technical effect is reduced by 60%, welding material is saved by 45%, and efficiency is increased by 50%; the mechanical properties of the weld are: tensile strength ≥800MPa, impact energy at -40℃ ≥47J; fatigue life reaches 90% of the gear body.

[0037] In summary, the gear mounting unit 200 includes a rotating motor and a horizontally positioned chuck 210 driven by the rotating motor. The horizontal arm 300 is adjustable in position along the length of the base 110 and mounted on the vertical slide 131. A welding wire spool 310 is provided at the rear end of the horizontal arm 300. The worktable 500 is mounted on the output end of the transverse drive unit 400 and is driven along the length of the horizontal arm 300. The position of the horizontal arm 300 is adjusted in two stages. The horizontal arm 300 itself is adjustable in position on the vertical slide 131, and with the assistance of the transverse drive unit 400, the position of the worktable 500 is easily adjustable. When not in operation, the worktable 500 can be retracted towards the horizontal arm 300 by the transverse drive unit 400, reducing the space occupied and the possibility of structural deformation at the end of the worktable 500.

[0038] In one embodiment, the transverse arm 300 includes a rear arm and a front arm telescopically disposed in the rear arm, and the transverse drive unit 400 is disposed in the front arm.

[0039] In this embodiment, considering the large length and mass of the crossarm 300, as well as the large mass of the components at its front end, the stable installation of the crossarm 300 is difficult. Therefore, designing the crossarm 300 as a telescopic type reduces the manufacturing difficulty and shortens the overall length of the crossarm 300 when not in operation or when a small extension is required. The telescopic form of the crossarm 300 can be varied; for example, a linear bearing can be added to the rear arm section, with the front arm mounted to the rear arm section via the linear bearing.

[0040] Reference Figures 3 to 4 In one embodiment, the welding wire spool 310 includes a spool base 311 and a rotating wheel 312 rotatably mounted on the spool base 311. A wire feed arm 313 is provided on the spool base 311, wherein the welding wire passes through the wire feed arm 313 from the rotating wheel 312 and is then guided into the welding wire output section 510.

[0041] In this embodiment, the base 311 serves as a fixed foundation to provide a fixing effect, the wheel 312 can be rotatably mounted on the base 311 via bearings, and the wire feeding arm 313 is provided on the base 311 to facilitate the feeding of the welding wire.

[0042] In one embodiment, the fixed angle of the wire-exiting arm 313 in the vertical plane is adjustable.

[0043] In this embodiment, different welding wires have different hardnesses and different setting angles, so that a certain adjustment and adaptation can be achieved in the vertical plane by means of the wire extension arm 313.

[0044] Reference Figures 3 to 4 In one embodiment, the end of the wire feeding arm 313 is slidably and rotatably provided with a roller 314 in the thickness direction of the rotating wheel 312, and a wire spool 315 for the welding wire to pass through is fixed on the roller 314, wherein the roller 314 is parallel to the central axis of the rotating wheel 312.

[0045] In this embodiment, the sliding of the roller 314 along the thickness direction of the rotating wheel 312 makes the wire feeding process smoother. For example, a fixed shaft is provided at the end of the wire feeding arm 313, and the roller 314 slides along the fixed shaft. The roller 314 can rotate, and a wire spool 315 is fixed on the roller 314. The welding wire passes through the roller 314 and is guided into the welding wire output section 510. The rotation of the roller 314 adapts to the gradual change of the wire feeding angle, and the sliding of the roller 314 on the fixed shaft adapts to the gradual change of the wire feeding position.

[0046] In one embodiment, the position of the wire spool 310 in the length direction of the cross arm 300 is adjustable.

[0047] In this embodiment, the adaptation to different types of welding wire is achieved by adjusting the position of the welding wire spool 310 on the horizontal arm 300. The specific adjustment method of the position of the welding wire spool 310 on the horizontal arm 300 can be varied, such as the welding wire spool 310 being clamped or snapped onto the horizontal arm 300.

[0048] In one embodiment, the lateral drive unit 400 operates as a linear motor drive.

[0049] In this embodiment, the operation mode of the transverse drive unit 400 is limited to linear motor drive, thereby achieving the required working accuracy.

[0050] In one embodiment, the path extension of the horizontal movement of the fixed rod 520 passes through the center of the chuck 210.

[0051] In this embodiment, the position of the fixing rod 520 is defined so that when the cross arm 300 extends to the appropriate position, the fixing rod 520 can serve as a marker to verify whether the cross arm 300 has retracted to the correct position. When the cross arm 300 has retracted to the correct position, the fixing rod 520 should be located at the center of the gear.

[0052] In one embodiment, the vertical drive unit 130 operates hydraulically.

[0053] In this embodiment, considering the large weight of the components mounted on the vertical drive unit 130, the working mode of the vertical drive unit 130 is restricted to hydraulic drive, which has the advantages of safety, reliability and stability.

[0054] In one embodiment, the vertical slide seat 131 is provided with a groove structure in the length direction of the base 110, the horizontal arm 300 is slidably installed in the groove structure, and a locking structure is provided on the vertical slide seat 131 corresponding to the horizontal arm 300.

[0055] In this embodiment, a method is provided for adjusting the position of the horizontal arm 300 on the vertical slide block 131. The horizontal arm 300 slides within the groove structure, and a locking structure is used to lock the horizontal arm 300. The locking structure can be implemented by a fixing pin or a fixing screw, etc.

[0056] In summary, the heavy-duty gear welding device provided by this utility model includes a gear mounting part 200 comprising a rotating motor and a horizontally arranged chuck 210 driven by the rotating motor. A horizontal arm 300 is adjustable in position on a vertical slide 131 along the length of the base 110. A welding wire spool 310 is provided at the rear end of the horizontal arm 300. A worktable 500 is mounted on the output end of a transverse drive part 400 and driven along the length of the horizontal arm 300. The position of the horizontal arm 300 is adjusted in two stages. The horizontal arm 300 itself is adjustable on the vertical slide 131, and with the assistance of the transverse drive part 400, the position of the worktable 500 is easily adjustable. During non-operation, the worktable 500 can be retracted towards the horizontal arm 300 via the transverse drive part 400, reducing space occupation and the possibility of structural deformation at the end of the worktable 500.

[0057] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural or procedural transformations made based on the content of the present utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present utility model.

Claims

1. A heavy-duty gear welding device, characterized in that, include: The base part (100) includes a base (110) and a support column (120) disposed at one end of the base (110) in the length direction. A vertical drive part (130) is provided on the support column (120), and the vertical drive part (130) drives a vertical slide (131) in the vertical direction. A gear mounting part (200) is mounted at the other end of the base (110) in the length direction. The gear mounting part (200) includes a rotating motor and a horizontally arranged chuck (210) driven by the rotating motor. A horizontal arm (300) is installed on the vertical slide (131) in an adjustable position along the length of the base (110). A wire spool (310) is provided at the rear end of the horizontal arm (300), wherein the wire spool (310) is used to install external welding wire. A lateral drive unit (400) is installed at the front end of the cross arm (300); A workbench (500) is mounted at the output end of the transverse drive unit (400) and driven along the length of the transverse arm (300). The workbench (500) is vertically downwardly provided with a welding wire output unit (510) and a fixing rod (520). The fixing rod (520) is connected to the lower end of the welding wire output unit (510). The welding wire output unit (510) drives and heat-melts the welding wire. The control center (600) connects and controls the operation of the gear mounting part (200), the horizontal drive part (400), the vertical drive part (130) and the welding wire output part (510); During the welding process, the vertical drive unit (130) is controlled to adjust its position in the vertical direction, and the rotary motor is controlled to drive the chuck (210) to rotate. The welding wire spool (310) includes a spool base (311) and a rotating wheel (312) rotatably mounted on the spool base (311). A wire feeding arm (313) is provided on the spool base (311). The welding wire passes through the wire feeding arm (313) from the rotating wheel (312) and is then guided into the welding wire output section (510). The fixed angle of the wire feeding arm (313) in the vertical plane is adjustable; The end of the wire feeding arm (313) is slidably and rotatably mounted on a roller (314) in the thickness direction of the rotating wheel (312). A wire spool (315) for the welding wire to pass through is fixed on the roller (314), wherein the roller (314) is parallel to the central axis of the rotating wheel (312).

2. The heavy-duty gear welding device according to claim 1, characterized in that, The transverse arm (300) includes a rear arm and a front arm telescopically disposed in the rear arm, and the transverse drive unit (400) is disposed in the front arm.

3. The heavy-duty gear welding device according to claim 1 or 2, characterized in that, The position of the wire spool (310) in the length direction of the cross arm (300) is adjustable.

4. The heavy-duty gear welding apparatus according to any one of claims 1 or 2, characterized in that, The operation of the lateral drive unit (400) is driven by a linear motor.

5. The heavy-duty gear welding apparatus according to any one of claims 1 or 2, characterized in that, The path extension of the fixed rod (520) moving in the horizontal direction passes through the center of the chuck (210).

6. The heavy-duty gear welding apparatus according to any one of claims 1 or 2, characterized in that, The vertical drive unit (130) operates in a hydraulically driven manner.

7. The heavy-duty gear welding apparatus according to any one of claims 1 or 2, characterized in that, The vertical slide (131) has a groove structure in the length direction of the base (110), the horizontal arm (300) is slidably installed in the groove structure, and the vertical slide (131) has a locking structure corresponding to the horizontal arm (300).

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