An automatic flame brazing machine for welding rotor end rings

Abstract

The utility model relates to an automatic flame brazing machine for welding rotor end ring, by main body mechanism, a plurality of welding module, and gas control electrical operation system three big module composition, wherein main body mechanism includes: main body frame, fixedly installed in the lower part of main body frame a plurality of groups of air inlet ring subassembly, the support component fixed on the main body frame, carousel and carousel drive mechanism fixed on the main body frame, a plurality of welding module even arrangement fixed on carousel, carousel drive mechanism drives carousel reciprocating rotation. The automatic flame brazing machine can be used for welding of different specifications of large rotor end ring, can improve the welding quality and welding efficiency, and can guarantee the stability and safety of equipment operation.

Description

Technical Field

[0001] This utility model belongs to the field of welding and relates to an automatic brazing machine, specifically an automatic flame brazing machine for welding rotor end rings. Background Technology

[0002] As core equipment for power generation, transmission, use, and energy characteristic conversion, electric motors are playing an increasingly important role. With advancements in manufacturing technology both domestically and internationally, electric motor products are also trending towards larger sizes. Currently, the outer diameter of the rotor in large electric motors is generally between 300-5000 mm. In motor manufacturing, the rotor and end rings are typically welded together using brazing. The brazed joint between the rotor and end rings serves both electrical conductivity and structural strength. During startup and operation, large electric motors experience significant centrifugal force, electromagnetic force, and thermal stress. To ensure electrical and mechanical performance, reliable electrical contact between the conductor bars and end rings is required, with a sufficiently large contact area and extremely high weld strength. The quality of the brazing between the rotor and end rings directly affects the performance and reliability of the motor. Therefore, end ring welding is a key technology in electric motor manufacturing.

[0003] Currently, there are two methods for welding large motor rotors to end rings: manual flame brazing and medium-frequency induction brazing.

[0004] The disadvantages of manual flame brazing are: 1) Welding slag will splatter on the workers during welding, and they also need to overcome the high temperature and heat generated by welding, which is labor-intensive and unsafe; 2) The welding quality depends entirely on the subjective judgment of the workers, and the skill level of the workers varies, which can easily lead to insufficient welding and welding defects such as porosity and cracks.

[0005] The disadvantages of medium-frequency induction brazing are: 1) The cost of a single medium-frequency welding coil used in large motors is extremely high, and the coil is a consumable part that needs to be replaced frequently. Each replacement requires a one-day production stoppage, resulting in high maintenance and operating costs; 2) The fixed position of the medium-frequency welding coil means that it can only be heated in a small area, making it difficult to meet the welding process requirements and resulting in scrap; 3) Due to the wide range of rotor and end ring diameters, various specifications of induction coils need to be manufactured, which significantly increases equipment costs. Moreover, replacing the induction coil also requires a certain amount of time, which is not conducive to improving production efficiency.

[0006] Therefore, there is a need to develop an automatic flame brazing machine suitable for welding the end rings of large rotors of different specifications. Summary of the Invention

[0007] To address the aforementioned technical problems, this utility model provides an automatic flame brazing machine for welding rotor end rings. It can be used for welding large rotor end rings of different specifications, improving welding quality and efficiency, and ensuring the stability and safety of equipment operation.

[0008] Therefore, this utility model provides an automatic flame brazing machine for welding rotor end rings, which consists of three main modules: a main body, multiple welding modules, and a pneumatic and electrical operating system. The main body includes: a main frame, several sets of air intake ring assemblies fixedly installed at the lower part of the main frame, support components installed on the main frame, a turntable, and a turntable drive mechanism fixed on the main frame; multiple welding modules are evenly arranged and fixed on the turntable, and the turntable drive mechanism drives the turntable to rotate back and forth.

[0009] In a preferred embodiment, the turntable drive mechanism includes a servo motor, a drive gear, and an external toothed rotary support. The turntable is fixed on the external toothed rotary support, and the drive gear drives the turntable to rotate back and forth by controlling the forward and reverse rotation of the motor.

[0010] In a preferred embodiment, the turntable drive mechanism includes a stepper motor and a linkage swing mechanism, with the turntable fixed to the linkage swing mechanism.

[0011] In a preferred embodiment, the welding module includes a flame sensor, a temperature sensor, multiple sets of burners or nozzles, an ignition assembly, a gas path assembly, a burner or nozzle position adjustment assembly, and an oscillation assembly.

[0012] In a preferred embodiment, the air circuit assembly of the welding module is connected to the air intake ring assembly on the main frame via a hose, with the hose having a slack.

[0013] In a preferred embodiment, the welding module includes two sets of upper and lower burners or nozzles, or three sets of upper, middle and lower burners or nozzles.

[0014] In a preferred embodiment, the support assembly includes a slide rail, a slider, a support column, and a locking element. The slide rail is fixed to the main frame, and the support column is fixed to the slider.

[0015] In a preferred embodiment, the support assembly includes a motor, a lead screw, a lead screw nut, and a support column. The servo motor is fixed to the main frame, and the support column is fixed to the lead screw nut.

[0016] In a preferred embodiment, the pneumatic electrical operating system includes an electrical control cabinet, an operating touch screen, and a pneumatic circuit control cabinet.

[0017] In a preferred embodiment, the pneumatic electrical operating system can automatically adjust the position of the burner or nozzle, automatically adjust the up-and-down swing of the burner or nozzle, automatically ignite, automatically extinguish, automatically adjust the flame, and automatically adjust the rotation speed and reciprocating rotation angle of the turntable.

[0018] In this automatic flame brazing machine, the support assembly for supporting the motor rotor and end ring is mounted on the main frame, enabling stable support for heavy, large rotors and end rings, expanding the applicability of the brazing machine and improving operational stability. Multiple welding modules are evenly arranged and fixed on the turntable, reducing the turntable's load-bearing capacity, simplifying the turntable transmission mechanism, and increasing the turntable's rotation speed range. The turntable drive mechanism drives the turntable to reciprocate at a certain angle, ensuring uniform heating of the rotor and end rings and preventing stress deformation caused by heat concentration. This automatic flame brazing machine can be used for welding large rotor end rings of different specifications, improving welding quality and efficiency, and ensuring the stability and safety of equipment operation. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the automatic flame brazing machine of this utility model used for welding rotors and end rings.

[0020] The components are: 1. Rotor; 2. End ring; 3. Intake ring; 4. Turntable; 5. Support column; 6. Welding module. Detailed Implementation

[0021] The technical solution of this utility model will be clearly and completely described below with reference to specific embodiments and examples. The embodiments and examples given are only for better illustrating this utility model, and not for limiting the scope of this utility model. Therefore, the numerical values, shapes, materials, constituent elements, the arrangement and connection of constituent elements, and the steps (processes) and the order of steps shown in the following embodiments are only examples and are not intended to limit this utility model. Therefore, any constituent elements in the following embodiments that are not described in the independent claims representing the highest concept of this utility model are arbitrary constituent elements. In addition, all the drawings are schematic diagrams. In the drawings, substantially the same structures are given the same reference numerals, and repeated descriptions are omitted or simplified. In addition, in the following embodiments, the terms "about" or "approximately" not only mean approximately, but also include manufacturing errors or dimensional tolerances.

[0022] This utility model provides an automatic flame brazing machine for welding rotor end rings, which consists of three main modules: a main body, multiple welding modules, and a pneumatic and electrical operating system. The main body includes: a main frame, several sets of air intake ring assemblies fixedly installed at the lower part of the main frame, support components installed on the main frame, a turntable, and a turntable drive mechanism fixed on the main frame; multiple welding modules are evenly arranged and fixed on the turntable, and the turntable drive mechanism drives the turntable to reciprocate.

[0023] Several sets of air intake ring assemblies are fixed to the outside of the main frame. The mixed gas (gas fuel + oxygen / air) required for flame brazing is input through the air intake rings, and the intelligent flow controller controls the flame by controlling the flow rate of the input gas.

[0024] The support assembly includes support columns, on which the rotor and end rings to be welded are placed. To accommodate rotors and end rings of different specifications, the support assembly is equipped with components for adjusting the radial distance of the support columns. Adjustment and positioning can be performed using various known methods. In a preferred embodiment, the support assembly includes a slide rail, a slider, a support column, and a locking element; the slide rail is fixed to the main frame, and the support column is fixed to the slider. In another preferred embodiment, the support assembly includes a motor, a lead screw, a lead screw nut, and a support column; the servo motor is fixed to the main frame, and the support column is fixed to the lead screw nut.

[0025] The turntable drive mechanism is used to drive the turntable and the welding module fixed on the turntable to reciprocate, and can employ various drive mechanisms known in the prior art. In a preferred embodiment, the turntable drive mechanism includes a servo motor, a drive gear, and an external gear rotary support. The turntable is fixed on the external gear rotary support, and the drive gear drives the turntable to reciprocate by controlling the forward and reverse rotation of the motor. In another preferred embodiment, the turntable drive mechanism includes a stepper motor and a linkage swing mechanism, and the turntable is fixed on the linkage swing mechanism.

[0026] Multiple welding modules are evenly arranged on the turntable. The required number of welding modules is selected according to the diameter of the end ring. The turntable drive mechanism drives the turntable to rotate back and forth, ensuring that the rotor and end ring are heated evenly, achieving welding without dead angles. For example, for welding an end ring with a diameter of 500mm, 6 welding modules can be selected, and the reciprocating rotation angle can be set to ±30°; for welding an end ring with a diameter of 1300mm, 12 welding modules can be selected, and the reciprocating rotation angle can be set to ±15°.

[0027] In a preferred embodiment, the welding module includes multiple sets of burners or nozzles, an ignition assembly, a gas path assembly, a burner or nozzle position adjustment assembly, and an oscillation assembly. In another preferred embodiment, the welding module further includes a flame sensor and a temperature sensor. One welding module is equipped with a temperature sensor to monitor the temperature in real time. The flame sensor monitors whether the nozzles are ignited. The temperature sensor monitors the product temperature and feeds it back to the gas control system. If the required temperature is not reached within a predetermined time, the intelligent flow controller increases the flow rate, increasing the flame size and heat of the nozzles; if the temperature is too high, the intelligent flow controller decreases the flow rate, reducing the nozzle size and heat.

[0028] In a preferred embodiment, the gas path assembly of the welding module is connected to the air intake ring assembly on the main frame via a hose, with a slack in the hose. In another preferred embodiment, the welding module includes upper and lower sets of burners or nozzles. In yet another preferred embodiment, the welding module includes upper, middle, and lower sets of burners or nozzles.

[0029] In a preferred embodiment, the pneumatic electrical operating system includes an electrical control cabinet, an operating touchscreen, and a pneumatic circuit control cabinet. In another preferred embodiment, the pneumatic electrical operating system can automatically adjust the position of the burner or nozzle, automatically adjust the up-and-down swing of the burner or nozzle, automatically ignite, automatically extinguish, automatically adjust the flame, and automatically adjust the rotation speed and reciprocating rotation angle of the turntable. The flame size can be controlled via a PLC intelligent touchscreen, or it can be automatically adjusted using a temperature sensor.

[0030] In use, first suspend the end ring onto the support column, then suspend the rotor onto the end ring, and fill the space between the end ring and the rotor with solder. After preparation, operate the touch screen to start the welding program: the required welding module is ignited, the burner or nozzle moves towards the end ring, and after reaching the designated position, the upper burner or nozzle heats and preheats the rotor and swings up and down for heating, while the lower burner heats and preheats the end ring and swings up and down for heating. The middle burner or nozzle can be selected to heat the solder between the end ring and the rotor at a fixed point; at the same time, the turntable rotates back and forth, driving the burner or nozzle of the welding module to rotate back and forth. The product of the number of ignited welding modules and the reciprocating rotation angle of the turntable is greater than or equal to 360 degrees to ensure that the rotor and the end ring are heated evenly. After welding is completed, each welding module returns to its original position and the flame is turned off, and the welding is completed.

[0031] This utility model's automatic flame brazing machine can be used for welding rotors and end rings of different specifications, with an outer diameter range covering 300-5000mm. Each large module is an independent unit, featuring a modular design, allowing for individual disassembly and replacement for maintenance and repair. Through the combined motion of multiple flame bars or nozzles in several welding modules, which oscillate up and down while reciprocating, the rotor and end rings being welded are ensured to be heated evenly. Preheating and welding are performed simultaneously, significantly improving welding efficiency and reducing welding time by two-thirds compared to traditional welding processes. According to a pre-set program, a series of mechanical movements are implemented, from automatic ignition to automatic welding, until welding is completed and the flame is automatically extinguished. During the welding process, the flow rate of the fuel gas and oxygen is automatically adjusted through temperature detection to control the flame size and meet the required welding temperature. This fully automated and intelligent system improves welding quality and efficiency while ensuring the stability and safety of equipment operation.

Claims

1. An automatic flame brazing machine for welding rotor end rings, characterized in that: It consists of three main modules: the main structure, multiple welding modules, and a pneumatic and electrical operating system. The main structure includes: a main frame, several sets of air intake ring assemblies fixedly installed at the lower part of the main frame, support components installed on the main frame, a turntable, and a turntable drive mechanism fixed on the main frame; multiple welding modules are evenly arranged and fixed on the turntable, and the turntable drive mechanism drives the turntable to rotate back and forth.

2. The automatic flame brazing machine according to claim 1, characterized in that: The turntable drive mechanism includes a servo motor, a drive gear, and an external toothed rotary support. The turntable is fixed on the external toothed rotary support, and the drive gear drives the turntable to rotate back and forth by controlling the forward and reverse rotation of the motor.

3. The automatic flame brazing machine according to claim 1, characterized in that: The turntable drive mechanism includes a stepper motor and a linkage swing mechanism, with the turntable fixed on the linkage swing mechanism.

4. The automatic flame brazing machine according to claim 1, characterized in that: The welding module includes a flame sensor, a temperature sensor, multiple sets of burners or nozzles, an ignition assembly, a gas path assembly, a burner or nozzle position adjustment assembly, and an oscillation assembly.

5. The automatic flame brazing machine according to claim 4, characterized in that: The air circuit assembly of the welding module is connected to the air intake ring assembly on the main frame via a hose, with a slack in the hose.

6. The automatic flame brazing machine according to claim 4, characterized in that: The welding module includes two sets of flame bars or nozzles, or three sets of flame bars or nozzles, either upper, middle, or lower.

7. The automatic flame brazing machine according to claim 1, characterized in that: The support assembly includes a slide rail, a slider, a support column, and a locking component. The slide rail is fixed to the main frame, and the support column is fixed to the slider.

8. The automatic flame brazing machine according to claim 1, characterized in that: The support assembly includes a motor, a lead screw, a lead screw nut, and a support column. The servo motor is fixed to the main frame, and the support column is fixed to the lead screw nut.

9. The automatic flame brazing machine according to claim 1, characterized in that: The pneumatic electrical operating system includes an electrical control cabinet, an operating touch screen, and a pneumatic circuit control cabinet.

10. The automatic flame brazing machine according to any one of claims 1 to 9, characterized in that: The pneumatic electrical operating system can automatically adjust the position of the burner or nozzle, automatically adjust the up-and-down swing of the burner or nozzle, automatically ignite, automatically extinguish, automatically adjust the flame, and automatically adjust the rotation speed and reciprocating rotation angle of the turntable.

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