An inner rib removing apparatus for an intercooler pipe

Abstract

The utility model discloses a kind of inner welding rib removing equipment for intercooler pipe, including rack, milling hole component, center clamping component and conveying component.Milling hole component is realized welding rib high-precision milling by displacement sensor and cylinder drive;Center clamping component uses the double-cylinder clamping mechanism and end face limiting mechanism of synchronous control, ensure that pipeline is positioned in the middle;Conveying component is realized self-adapting support vibration reduction by spring-wedge block-support ball structure.The equipment solves the problem of low machining precision and poor adaptability in the prior art, has the advantages of high machining efficiency, good welding rib removal consistency and small vibration, and is suitable for batch processing of intercooler pipe in automobile manufacturing and other industries.

Description

Technical Field

[0001] This utility model relates to the field of intercooler manufacturing technology, and in particular to a device for removing internal weld beads from intercooler tubes. Background Technology

[0002] The intercooler is a key component of a turbocharged engine system, used to reduce the temperature of the boosted air to improve engine efficiency. Internally, it consists of multiple parallel, thin-walled metal pipes. During manufacturing, the pipe walls are typically joined using a high-frequency welding process, resulting in ring-shaped weld beads on the inner wall of the pipes. If these weld beads are not thoroughly removed, the following problems can occur: 1. Increased fluid resistance: The protruding weld beads significantly increase the flow resistance of the cooling air, reducing the intercooler's heat exchange efficiency; 2. Stress concentration risk: Stress concentration occurs at the base of the weld beads, and long-term impact from high-pressure airflow can easily lead to pipe fatigue cracking; 3. Inadequate cleanliness: Residual weld beads may detach and form metal shavings, contaminating the engine cooling system.

[0003] Currently, the industry mainly adopts the following two methods for removing weld beads: 1. Manual grinding: Weld beads are manually ground by grinding wheel or file, which has problems such as low efficiency, high labor intensity, and difficulty in ensuring processing accuracy. It is also easy to cause scratches on the inner wall of the pipe due to improper operation. 2. Automated milling equipment: Although existing automated equipment can achieve batch removal of weld beads, it still has the following defects: (1) The clamping mechanism cannot ensure the pipe is centered and is prone to uneven milling depth due to eccentricity; (2) The rigid support structure of the conveying component cannot adapt to pipes of different diameters, and the vibration amplitude is large, affecting the processing surface quality; (3) The milling cutter feed mechanism lacks real-time position feedback and relies on preset parameters, making it difficult to cope with the pipe wall thickness tolerance.

[0004] Therefore, there is an urgent need for an automated weld bead removal device that can achieve precise centering and positioning of pipelines, adaptive support, and real-time position adjustment, in order to improve processing efficiency and quality stability. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the defects of the prior art and provide a device for removing internal weld beads for intercooler tubes.

[0006] To solve the above-mentioned technical problems, this utility model provides the following technical solution: This utility model discloses a device for removing internal weld beads from intercooler pipes, comprising a frame on which a milling assembly, a centering clamping assembly, and a conveying assembly are sequentially fixed. The milling assembly includes a milling cutter mechanism that feeds along the pipe axial direction for milling the weld beads on the inner wall of the pipe. The centering clamping assembly includes clamping mechanisms symmetrically arranged on both sides of the pipe and a limiting mechanism arranged on the pipe end face for clamping the pipe and limiting its axial displacement. The conveying assembly includes multiple floating support mechanisms arranged along the pipe conveying direction for supporting the pipe and reducing vibration during conveying. The milling assembly, centering clamping assembly, and conveying assembly are arranged sequentially along the pipe processing direction, with the centering clamping assembly located between the milling assembly and the conveying assembly to fix the pipe position before milling.

[0007] As a preferred embodiment of this utility model, the milling assembly includes two parallel milling cutter support slide rails fixed to the frame, a horizontal fixing plate fixed to the milling cutter support slide rails, a guide rail drive cylinder fixed to the inner side of the frame and connected to the bottom of the horizontal fixing plate for driving the horizontal fixing plate to move along the milling cutter support slide rails, a milling cutter spindle fixed above the horizontal fixing plate, a displacement sensor parallel to the milling cutter spindle for detecting the position of the milling cutter spindle, a vertical fixing plate fixed to one end of the horizontal fixing plate, a milling cutter drive motor and a drive pulley fixed to the side of the vertical fixing plate, and multiple internal milling cutters fixed to the end of the milling cutter spindle. The drive pulley is connected to the driven pulley on the milling cutter spindle via a belt for transmitting power. The piston rod of the guide rail drive cylinder is fixedly connected to the vertical fixing plate via a connecting block for pushing the horizontal fixing plate to move and adjust the relative position of the internal milling cutter and the inner wall of the pipe.

[0008] As a preferred embodiment of this utility model, the central clamping assembly includes two semi-circular clamping drive mechanisms disposed opposite to each other on both sides of the pipe for clamping the pipe from both sides. An end-face limiting mechanism is disposed on the end face of the pipe for limiting the axial displacement of the pipe. The semi-circular clamping drive mechanism includes a semi-circular clamping block, a clamping block support slide, a floating joint, and a clamping drive cylinder. The clamping block support slide is fixed to the bottom of the semi-circular clamping block, the floating joint is fixed to the side of the semi-circular clamping block, the piston rod of the clamping drive cylinder is fixedly connected to the floating joint, and the clamping drive cylinder is fixedly mounted on a cylinder mounting bracket. The upper part is used to drive the clamping block support slide to move the semi-circular clamping block. The two semi-circular clamping drive mechanisms are linked by a synchronization mechanism. The synchronization mechanism includes a synchronization control valve for synchronously supplying or exhausting air to the air circuits of the two clamping drive cylinders. The end face limiting mechanism includes a positioning rod, a U-shaped fixed bracket and a lifting cylinder. The middle part of the positioning rod is hinged to the inner side of the U-shaped fixed bracket by a pin. One end of the positioning rod is provided with a circular boss, and the other end is hinged to the piston rod of the lifting cylinder by a connector. The lifting cylinder is fixedly installed on the frame to drive the positioning rod to rotate around the hinge point so that the circular boss contacts the end face of the pipe.

[0009] As a preferred technical solution of this utility model, the conveying assembly includes several floating support brackets arranged along the pipeline conveying direction. Each floating support bracket includes a wedge block, a support ball rotatably connected to the middle of the wedge block, and four springs symmetrically distributed at the bottom of the wedge block. The upper end of the springs is fixed to the bottom of the wedge block, and the lower end is fixed to the conveying fixing plate. The conveying fixing plate is fixed to the frame to support the bottom of the springs. The wedge block and the support ball are rotatably connected through a ball fixing seat. The springs are used to provide elastic support force to the wedge block so that the support ball can adaptively adjust the support height according to the outer diameter of the pipeline.

[0010] As a preferred embodiment of this utility model, the two semi-circular clamping drive mechanisms are symmetrically arranged on both sides of the pipe to be processed, and the end face limiting mechanism is located between the two clamping drive mechanisms.

[0011] As a preferred technical solution of this utility model, the plurality of floating support brackets are arranged at equal intervals on the frame along the pipeline conveying direction to form a continuous support track.

[0012] In a preferred embodiment of this invention, the milling cutter spindle is fixed to a horizontal fixed plate via a bearing seat.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. By using a displacement sensor to detect the position of the milling cutter spindle in real time, and combining it with the axial feed control of the guide rail drive cylinder, the weld bead removal depth error can be controlled within ≤0.05mm, significantly improving machining accuracy; 2. The symmetrically arranged semi-circular clamping mechanism is driven by the synchronous control valve to ensure uniform radial force on the pipeline and avoid processing defects caused by eccentricity. At the same time, the end face limiting mechanism can limit the axial movement of the pipeline to ≤0.1mm. 3. The floating support bracket has a three-stage structure of spring-wedge block-support ball, which can adaptively adjust the support height. Combined with the rotatable design of the support ball, the vibration amplitude of the conveyor is reduced to ≤0.1mm, which significantly improves the processing stability of thin-walled pipes (wall thickness ≤1.5mm). Attached Figure Description

[0014] 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: Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is the front view of this utility model; Figure 3 This is a top view of the present invention; Figure 4 This is a side view of the present invention; Figure 5 This is a cross-sectional structural diagram of the present invention; Figure 6 This is a schematic diagram of the end face limiting mechanism of this utility model; Figure 7 This is a schematic diagram of the conveying component in this utility model; In the diagram: 1. Frame; 2. Milling assembly; 3. Centering clamping assembly; 4. Conveying assembly; 21. Milling cutter support slide rail; 22. Horizontal fixed plate; 23. Guide rail drive cylinder; 24. Milling cutter spindle; 25. Displacement sensor; 26. Vertical fixed plate; 27. Milling cutter drive motor; 28. Drive pulley; 29. ​​Internal milling cutter; 31. Clamping drive mechanism; 32. End face limiting mechanism; 41. Floating support bracket; 231. Connecting block; 241. Bearing 242. Driven pulley; 311. Semi-circular clamping block; 312. Clamping block support slide; 313. Floating joint; 314. Clamping drive cylinder; 315. Cylinder mounting bracket; 316. Synchronization mechanism; 321. Positioning rod; 322. U-shaped fixed bracket; 323. Lifting cylinder; 411. Wedge block; 412. Support ball; 413. Spring; 414. Conveying fixed plate; 415. Ball fixing seat; 3161. Synchronization control valve. Detailed Implementation

[0015] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0016] In the attached diagram, all identical reference numerals refer to the same components.

[0017] Example 1: Basic intercooler tube weld bead removal equipment, such as Figure 1-7 The embodiment shown is a standardized device suitable for conventional intercooler tubes (diameter Φ30mm~Φ60mm, wall thickness 1.0mm~1.5mm). The structure and connection relationship of each component are as follows: Milling Assembly 2: The milling cutter support slide rail 21 is horizontally fixed to the frame 1, with a 200mm gap between the two slide rails. The surface is chrome-plated to reduce frictional resistance. The horizontal fixing plate 22 is bolted to the milling cutter support slide rail 21, and its bottom is rigidly connected to the piston rod of the guide rail drive cylinder 23 via a connecting block 231. The cylinder stroke is 50mm, and the thrust is 200N. The milling cutter spindle 24 is vertically mounted above the horizontal fixing plate 22 and fixed via a bearing seat 241. The spindle speed range is 1000~3000r / min. Displacement sensor... 25 is mounted parallel to the side of the milling cutter spindle 24, with a detection accuracy of 0.01mm, and is used for real-time feedback of the spindle's axial position; the vertical fixing plate 26 is vertically fixed to one end of the horizontal fixing plate 22, and the milling cutter drive motor 27 and drive pulley 28 are mounted on its side by bolts, with a motor power of 2kW; the drive pulley 28 is connected to the driven pulley 242 at the end of the milling cutter spindle 24 by a synchronous belt, with a transmission ratio of 1:1.5; three internal milling cutters 29 with a diameter of Φ28mm and a cutting edge angle of 60° are fixed to the end of the milling cutter spindle 24 by threads.

[0018] Please see Figure 6 The central clamping assembly 3 consists of two semi-circular clamping drive mechanisms 31 symmetrically arranged on both sides of the pipe. The clamping block support slide 312 is connected to the frame 1 via a linear guide rail. One end of the floating joint 313 is connected to the piston rod of the clamping drive cylinder 314, and the other end is fixed to the clamping block support slide 312. The clamping drive cylinder 314 has a stroke of 100mm and a thrust of 150N. The synchronous extension and retraction of the two cylinders is achieved through the synchronous control valve 3161, with a synchronous error ≤0.1mm. The positioning rod 321 of the end face limiting mechanism 32 is hinged to the inner side of the U-shaped fixed bracket 322 via a pin. Its circular boss has a diameter of Φ32mm and applies a pressure of 50N when in contact with the pipe end face. The lifting cylinder 323 has a stroke of 50mm and a thrust of 100N, and is used to drive the positioning rod 321 to rotate 90°.

[0019] Please see Figure 7 Conveying component 4: Floating support brackets 41 are arranged at equal intervals along the pipeline conveying direction, with a spacing of 150mm; the bottom of the wedge block 411 is connected to the conveying fixing plate 414 through 4 springs 413, with a spring stiffness of 50N / mm and a pre-compression of 10mm; the support ball 412 is connected to the middle of the wedge block 411 through the ball fixing seat 415, and the support ball 412 is a wear-resistant steel ball with a diameter of Φ50mm; the conveying fixing plate 414 is fixed to the frame 1 by bolts and is used to support the bottom of the springs 413.

[0020] The working process of this equipment is as follows: 1. The pipeline to be processed is supported by the conveying assembly 4 and conveyed to the processing station. The central clamping assembly 3 drives two clamping drive cylinders 314 to extend and retract synchronously through the synchronous control valve 3161, which pushes the clamping block support slide 312 to drive the semi-circular clamping block 311 to move along the linear guide rail and clamp the pipeline from both sides. 2. At the same time, the lifting cylinder 323 drives the positioning rod 321 to rotate, so that the circular boss contacts the end face of the pipe, thus limiting the axial displacement of the pipe. 3. The milling assembly 2 pushes the horizontal fixed plate 22 along the milling cutter support slide rail 21 through the guide rail drive cylinder 23 to adjust the relative position of the inner hole milling cutter 29 and the inner wall of the pipe. The displacement sensor 25 detects the axial position of the milling cutter spindle 24 in real time and feeds it back to the control system. The milling cutter drive motor 27 drives the milling cutter spindle 24 to rotate through the drive pulley 28. The inner hole milling cutter 29 performs milling processing on the weld bead of the inner wall of the pipe.

[0021] Example 2: Equipment for removing weld beads inside large-diameter intercooler tubes This embodiment is applicable to large-diameter intercooler tubes (diameter Φ60mm~Φ100mm, wall thickness 1.5mm~2.5mm), and the following components are improved based on Embodiment 1: Milling Assembly 2: The spacing of the milling cutter support slide rails 21 is adjusted to 300mm to enhance stability; the speed range of the milling cutter spindle 24 is adjusted to 500~2000r / min to meet the needs of large-diameter pipe processing; the number of internal milling cutters 29 is increased to 4, with a cutter diameter of Φ55mm and a cutting edge angle adjusted to 45° to improve cutting efficiency. Centering Clamping Assembly 3: The thrust of the clamping drive cylinder 314 is increased to 200N to meet the clamping force requirements of larger pipe diameters; the synchronous control valve 3161 adds a pressure compensation function, further controlling the synchronization error to ≤0.05mm. Conveying Assembly 4: The stiffness of the spring 413 is adjusted to 80N / mm to support the weight of larger diameter pipes; the diameter of the support ball 412 is increased to Φ60mm to improve load-bearing capacity.

[0022] When the equipment is working, by adjusting the spindle speed of the milling cutter 24 and the number of internal milling cutters 29, combined with enhanced clamping and supporting forces, efficient milling of large-diameter intercooler tubes can be achieved.

[0023] Example 3: High-precision equipment for removing weld beads inside intercooler tubes This embodiment is applicable to intercooler tubes with high precision requirements (tube diameter Φ20mm~Φ40mm, wall thickness 0.8mm~1.2mm). Based on embodiment 1, the following components are optimized: Milling Assembly 2: The displacement sensor 25 has its detection accuracy improved to 0.005mm for more precise position control; the milling cutter drive motor 27 has its power reduced to 3kW to reduce cutting vibration, and the spindle speed range has been adjusted to 1500~4000r / min to improve the surface finish. Centering Clamping Assembly 3: The stroke of the clamping drive cylinder 314 has been shortened to 80mm to accommodate small-diameter clamping; the synchronization control valve 3161 has been enhanced with flow regulation, and the synchronization error is controlled to ≤0.03mm. Conveying Assembly 4: The stiffness of the spring 413 has been reduced to 30N / mm to meet the adaptive support requirements of small-diameter pipes; the diameter of the support ball 412 has been reduced to Φ40mm to improve the positioning accuracy of small-diameter pipes.

[0024] When the equipment is working, it uses a high-precision displacement sensor 25 and an optimized synchronous control valve 3161, combined with a low-vibration milling cutter drive motor 27, to achieve high-precision removal of weld beads from thin-walled, small-diameter intercooler tubes.

[0025] This utility model is a device for removing internal weld beads from intercooler tubes. Through the combination of structural innovation and intelligent control technology, it solves the technical problems of low processing accuracy and poor adaptability in the existing technology, and has significant economic benefits and market application value.

[0026] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A device for removing internal weld beads from intercooler tubes, comprising a frame (1), characterized in that: The milling assembly (2), the centering clamping assembly (3), and the conveying assembly (4) are fixed sequentially on the frame (1). The milling assembly (2) includes a milling cutter mechanism that feeds along the pipe axial direction for milling the weld bead on the inner wall of the pipe. The centering clamping assembly (3) includes clamping mechanisms symmetrically arranged on both sides of the pipe and a limiting mechanism arranged on the end face of the pipe for clamping the pipe and limiting its axial displacement. The conveying assembly (4) includes multiple floating support mechanisms arranged along the pipe conveying direction for supporting the pipe and reducing vibration during the conveying process. The milling assembly (2), the centering clamping assembly (3), and the conveying assembly (4) are arranged sequentially along the pipe processing direction, and the centering clamping assembly (3) is located between the milling assembly (2) and the conveying assembly (4) for fixing the pipe position before milling.

2. The equipment for removing internal weld beads from intercooler tubes according to claim 1, characterized in that, The milling assembly (2) includes two parallel milling cutter support slide rails (21) fixed to the frame (1), a horizontal fixing plate (22) fixed to the milling cutter support slide rails (21), a guide rail drive cylinder (23) fixed to the inside of the frame (1) and connected to the bottom of the horizontal fixing plate (22) for driving the horizontal fixing plate (22) to move along the milling cutter support slide rails (21), a milling cutter spindle (24) fixed above the horizontal fixing plate (22), a displacement sensor (25) set parallel to the milling cutter spindle (24) for detecting the position of the milling cutter spindle (24), and a vertical fixing plate (26). Fixed to one end of the horizontal fixed plate (22), the milling cutter drive motor (27) and drive pulley (28) are fixed to the side of the vertical fixed plate (26), and multiple internal milling cutters (29) are fixed to the end of the milling cutter spindle (24). The drive pulley (28) is connected to the driven pulley (242) on the milling cutter spindle (24) via a belt to transmit power. The piston rod of the guide rail drive cylinder (23) is fixedly connected to the vertical fixed plate (26) via a connecting block (231) to push the horizontal fixed plate (22) to move and adjust the relative position of the internal milling cutter (29) and the inner wall of the pipe.

3. The equipment for removing internal weld beads from intercooler tubes according to claim 1, characterized in that, The central clamping assembly (3) includes two semi-circular clamping drive mechanisms (31) arranged opposite to each other on both sides of the pipe for clamping the pipe from both sides. An end-face limiting mechanism (32) is arranged on the end face of the pipe for limiting the axial displacement of the pipe. The semi-circular clamping drive mechanism (31) includes a semi-circular clamping block (311), a clamping block support slide (312), a floating joint (313), and a clamping drive cylinder (314). The clamping block support slide (312) is fixed to the bottom of the semi-circular clamping block (311), the floating joint (313) is fixed to the side of the semi-circular clamping block (311), the piston rod of the clamping drive cylinder (314) is fixedly connected to the floating joint (313), and the clamping drive cylinder (314) is fixedly mounted on the cylinder mounting bracket (315) for driving the clamping block support slide (311). 2) Drive the semi-circular clamping block (311) to move. The two semi-circular clamping drive mechanisms (31) are linked by a synchronization mechanism (316). The synchronization mechanism (316) includes a synchronization control valve (3161) for synchronously supplying or exhausting air to the air passages of the two clamping drive cylinders (314). The end face limiting mechanism (32) includes a positioning rod (321), a U-shaped fixed bracket (322), and a lifting cylinder (323). The middle part of the positioning rod (321) is hinged to the inner side of the U-shaped fixed bracket (322) by a pin. One end of the positioning rod (321) is provided with a circular boss, and the other end is hinged to the piston rod of the lifting cylinder (323) by a connector. The lifting cylinder (323) is fixedly installed on the frame (1) for driving the positioning rod (321) to rotate around the hinge point so that the circular boss contacts the end face of the pipe.

4. The equipment for removing internal weld beads from intercooler tubes according to claim 1, characterized in that, The conveying assembly (4) includes several floating support brackets (41) arranged along the pipeline conveying direction. Each floating support bracket (41) includes a wedge block (411), a support ball (412) rotatably connected to the middle of the wedge block (411), and four springs (413) symmetrically distributed at the bottom of the wedge block (411). The upper end is fixed to the bottom of the wedge block (411), and the lower end is fixed to the conveying fixing plate (414). The conveying fixing plate (414) is fixed to the frame (1) to support the bottom of the springs (413). The wedge block (411) and the support ball (412) are rotatably connected through a ball fixing seat (415). The springs (413) are used to provide elastic support force for the wedge block (411) so that the support ball (412) can adaptively adjust the support height according to the outer diameter of the pipeline.

5. The equipment for removing internal weld beads from intercooler tubes according to claim 3, characterized in that, The two semi-circular clamping drive mechanisms (31) are symmetrically arranged on both sides of the pipe to be processed, and the end face limiting mechanism (32) is located between the two clamping drive mechanisms (31).

6. The equipment for removing internal weld beads from intercooler tubes according to claim 4, characterized in that, The plurality of floating support brackets (41) are arranged at equal intervals on the frame (1) along the pipeline conveying direction to form a continuous support track.

7. The equipment for removing internal weld beads from intercooler tubes according to claim 2, characterized in that, The milling cutter spindle (24) is fixed to the horizontal fixed plate (22) by bearing seat (241).

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