Road roller frame and manufacturing method therefor, and road roller
The integrally cast road roller frame with hollow designs and tungsten carbide coatings addresses the inefficiencies of traditional manufacturing, achieving significant weight reduction and improved durability for construction machinery.
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- JIANGSU XCMG CONSTRUCTION MACHINERY RESEARCH INSTITUTE LTD
- Filing Date
- 2024-12-02
- Publication Date
- 2026-04-29
AI Technical Summary
Traditional road roller frame manufacturing methods face issues such as large processing workload, numerous procedures, and difficult control of welding quality, leading to insufficient lightweight and fatigue failure in weld seams, making them unsuitable for harsh construction conditions.
The road roller frame is integrally formed by casting, with components like the front and rear frames being hingedly connected, and features hollow designs and tungsten carbide coatings to enhance wear resistance, reducing weight and improving structural integrity.
This approach reduces processing procedures by over 50%, achieves a 20% weight reduction, and enhances fatigue life and wear resistance by over 30%, making it suitable for harsh construction environments.
Smart Images
Figure IMGAF001_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present disclosure relates to the technical field of construction machinery, and in particular to road roller frames, manufacturing methods thereof, and road roller.BACKGROUND ART
[0002] Traditional processing means for road roller frames usually involve stamping and tailor-welding. These means have issues such as large processing workload, numerous procedures, and difficult control of welding quality, which result in insufficient lightweight of the frame and fatigue failure prone to occur in the heat-affected zone of weld seams, making it unable to adapt to the harsh working conditions of construction machinery.
[0003] Currently, efforts to improve production efficiency and frame quality usually focus on welding, such as designing new welding fixtures and adopting automation. Compared with conventional welding techniques, these methods do not fundamentally change the number of assemblies or welding procedures. They still suffer from issues like large processing workload, numerous procedures, and difficult control of welding quality. These issues lead to insufficient lightweight of the frame, fatigue failure prone to occur in the heat-affected zone of weld seams, and easy wear failure at the bottom of the water tank support and power compartment, making it unable to adapt to the harsh working conditions of construction machinery.SUMMARY
[0004] The present disclosure provides a road roller frame, including: a front frame; and a rear frame hingedly connected to the front frame; wherein at least one of the front frame and the rear frame is integrally formed by casting.
[0005] In some embodiments, the front frame includes: a first longitudinal side wall and a second longitudinal side wall arranged in parallel; and an oil tank support, a cab support and a water tank support, all of which are fixedly arranged between the first longitudinal side wall and the second longitudinal side wall.
[0006] In some embodiments, the road roller frame includes a first longitudinal bracket located between the first longitudinal side wall and the second longitudinal side wall, wherein the first longitudinal bracket connects the oil tank support with the cab support; the oil tank support and the cab support enclose to form a hollow rectangular frame; and the first longitudinal bracket divides the rectangular frame into two hollow small rectangular frames.
[0007] In some embodiments, the cab support is configured in an I-shaped structure, and include a first transverse bracket, a second transverse bracket and a second longitudinal bracket, wherein the first transverse bracket and the second transverse bracket are arranged at intervals along a longitudinal direction of the frame; the second longitudinal bracket is connected to the first transverse bracket and the second transverse bracket respectively; and the first transverse bracket is connected to the oil tank support.
[0008] In some embodiments, the water tank support is located below the cab support, and includes two sub-brackets extending along the longitudinal direction of the frame, and the two sub-brackets are symmetrically arranged relative to the longitudinal central plane of the frame, and the area between the two sub-brackets is hollow.
[0009] In some embodiments, the water tank support is located at a bottom of the front frame, and a bottom of the water tank support is provided with a tungsten carbide coating.
[0010] In some embodiments, the road roller frame includes a hinge post located between the oil tank support and the water tank support for connection with the hinging device that hingedly connects the front frame to the rear frame.
[0011] In some embodiments, the road roller frame includes a support frame located between the first longitudinal side wall and the second longitudinal side wall, wherein the cab support, the water tank support and the hinge post are all connected to the support frame.
[0012] In some embodiments, the rear frame includes: a third longitudinal side wall and a fourth longitudinal side wall arranged in parallel; and a radiator support, a battery support, a power compartment support and a hinge interface portion, all of which are fixedly arranged between the third longitudinal side wall and the fourth longitudinal side wall.
[0013] In some embodiments, viewed from the longitudinal side of the frame, the third longitudinal side wall or the fourth longitudinal side wall forms an L-shaped structure with the power compartment support.
[0014] In some embodiments, viewed from the top of the frame, the third longitudinal side wall, the fourth longitudinal side wall, the radiator support, and the power compartment support enclose to form a hollow rectangular frame.
[0015] In some embodiments, the radiator support and the battery support are arranged side by side along a transverse direction of the frame, and both are provided with a rectangular opening.
[0016] In some embodiments, the hinge interface portion is arranged at the longitudinal front end of the rear frame for installation of a hinge device that hingedly connects the front frame and the rear frame.
[0017] In some embodiments, the power compartment support is located at a bottom of the rear frame, and a bottom of the power compartment support is provided with a tungsten carbide coating.
[0018] In another aspect, the present disclosure provides a road roller including the aforementioned road roller frame.
[0019] In a further aspect, the present disclosure provides a manufacturing method for the road roller frame, including: integrally forming at least one of the front frame and the rear frame by a casting process; and hingedly connecting the front frame to the rear frame.
[0020] In some embodiments, the casting process is one of sand casting, lost foam casting and counter-gravity casting.
[0021] In some embodiments, the casting process includes the following steps: mold-fabricating: fabricating a sand mold and a sand core according to the models of the front frame and / or the rear frame; coating-brushing: brushing coating onto the sand mold and the sand core, and then drying a coated layer; core-setting and flask-placing: putting the sand mold and the sand core into a flask, and laying tungsten carbide particles in the sand mold in an area corresponding to a water tank support of the front frame or in an area corresponding to a bottom of a power compartment support of the rear frame; melting and pouring: melting raw materials into a liquid state, and pouring the raw materials into the sand mold, wherein a composition of the raw materials is as follows: C: 0.30%, Si: 0.05%, Mn: 0.70%, Nb: 0.008%, V: 0.015%, Ni: 0.6%, Cr: 0.30%, P: ≤0.020%, S: ≤0.005%, and the balance is Fe; and shakeout and part-removal: after a frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then carrying out treatments such as shot blasting, machining or the like to produce a qualified frame sample.
[0022] In some embodiments, the casting process includes the following steps: mold-fabricating: fabricating a mold according to the models of the front frame and / or the rear frame; core-making and core-repairing: making a sand core and repairing the sand core; coating-brushing: brushing coating onto the sand core, and then drying a coated layer; sand molding: mixing new sand, used sand and auxiliary materials for sand molding, with an addition amount of resin being 1-2% of the total sand weight; core-setting and flask-closing: putting the sand core into a flask, closing upper and lower flasks, and laying tungsten carbide particles in a sand mold in an area corresponding to a water tank support of the front frame or in an area corresponding to the bottom of a power compartment support of the rear frame; melting and pouring: melting raw materials, a composition of which is as follows: C: 0.20%, Si: 0.1%, Mn: 0.6%, Nb: 0.005%, V: 0.010%, Ni: 0.5%, Cr: 0.20%, P: ≤0.020%, S: ≤0.005%, and the balance is Fe; and pouring the raw materials into the sand mold, allowing it to be cooled and solidified in the mold, wherein the pouring temperature is controlled at 1620°C; and shakeout and part-removal: after a frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then shot-blasting and machining to obtain the front frame and / or the rear frame.
[0023] In some embodiments, the casting process includes the following steps: mold-fabricating: fabricating a mold according to the models of the front frame and / or the rear frame; coating-brushing: brushing coating onto a shell mold, and then drying a coated layer; placing into flask: placing a sand mold in a flask, pouring a mixture of raw sand and steel balls into the gap between the flask and the sand mold and meanwhile vibrating with a vibrating plate; and laying tungsten carbide particles in the sand mold in an area corresponding to the water tank support of the front frame or in an area corresponding to a bottom of the power compartment support of the rear frame; melting and pouring: melting raw materials, a composition of which is as follows: C : 0.40%, Si: 0.4%, Mn: 1%, Nb: 0.03%, V: 0.030%, Ni : 1%, Cr: 0.50%, P : ≤0.020%, S : ≤0.005%, and the balance is Fe; pouring the raw materials into the sand mold, allowing it to be cooled and solidified in the mold, wherein the pouring temperature is controlled at 1650°C; and shakeout and part-removal: after a frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then shot-blasting and machining to obtain the front frame and / or the rear frame.
[0024] In the road roller frame disclosed in the present disclosure, a plurality of separate, discrete parts such as guard plates on both sides of the frame, the cab support, the bottom support and so on are integrally formed, which achieves high integration and lightweight, reduces processing procedures, shortens processing cycle, and improves production efficiency.
[0025] Other features and advantages of the present disclosure will become clear through the following detailed description of exemplary embodiments of the present disclosure with reference to the attached drawings.BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings described herein are provided for further understanding of the present disclosure and constitute part of the present disclosure. The illustrative embodiments of the present disclosure and their descriptions are used to explain the present disclosure and do not constitute undue limitations on the present disclosure. In the figures: FIG.1 is a schematic structural view of a front frame according to an embodiment of the present disclosure; and FIG.2 is a schematic structural view of a rear frame according to an embodiment of the present disclosure. DETAILED DESCRIPTION
[0027] The technical solutions in the embodiments of the present disclosure will be clearly and completely described with reference to the drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only part of the embodiments of the present disclosure other than the whole embodiments. The following description for at least one exemplary embodiment is merely illustrative in actual and is in no way intended to limit the present disclosure and its application or uses. All other embodiments that are obtained by those skilled in the art based on the embodiments of the present disclosure without paying inventive effort fall within the protection scope of the present disclosure.
[0028] Unless otherwise specified, the relative arrangement of components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present disclosure. It should be understood that the dimensions of various parts shown in the drawings are not drawn to actual scale for the sake of convenience in description. Techniques, methods and equipment known to those skilled in the art in the related art may not be discussed in detail, but they should be regarded as part of the granted description under appropriate circumstances. In all examples shown and discussed herein, any specific values should be interpreted as illustrative only and not as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters denote similar items in the following drawings. Thus, once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.
[0029] In the depiction of the present disclosure, it should be understood that the words "first", "second" and the like are used to define parts only for the convenience of distinguishing the corresponding parts from each other. Unless otherwise stated, the above words have no special meaning, and thus shall not be construed as limiting the scope of protection of the present disclosure.
[0030] In the depiction of the present disclosure, it should be understood that the orientation or positional relationship indicated by words describing orientation such as "front, back, up, down, left, right", "lateral, vertical, perpendicular, horizontal" and "top, bottom" is usually based on the attached drawings shown, just for the convenience of describing the present disclosure and simplifying the depiction. Unless otherwise stated, these words describing orientation do not indicate or imply that the indicated devices or elements must have a specific orientation, or be constructed and operated in a specific orientation, so they shall not be construed as restricting the scope of protection of the present disclosure. The words "inside, outside" refer to the inside and outside relative to the contour of a component itself.
[0031] The present disclosure provides a road roller frame. The road roller frame includes a front frame 100, a rear frame 200, and a connection mechanism such as a hinging device. The front frame 100 and the rear frame 200 are hinged together via the connection mechanism, and both the front frame 100 and the rear frame 200 are integrally molded by casting.
[0032] Both the front frame and the rear frame are components integrally formed by casting. On one hand, this is conducive to improving material utilization rate; on the other hand, it helps to enhance the forming flexibility of the road roller frame. This in turn facilitates the rational configuration of the structure, shape, parameters, connection relationship and weight reduction process of each functional part while ensuring the workpiece strength, and helps to simplify the structural design of the front frame 100 and the rear frame 200, thereby contributing to the realization of lightweight of the road roller frame.
[0033] As shown in FIG.1, the present disclosure provides a road roller frame including a front frame 100 and a rear frame 200. The rear frame 200 is hingedly connected to the front frame 100 via a hinge device. One or both of the front frame 100 and the rear frame 200 are of plate-type structure integrally formed by casting, which means that all parts of the front frame 100 and the rear frame 200 are composed of plate-like pieces. This is conducive to enhancing the structural rigidity of the road roller frame, improving the reliability of the road roller frame, and contributing to the overall lightweight of the frame.
[0034] As shown in FIG.1, the front frame 100 includes a first longitudinal side wall 110 and a second longitudinal side wall 120 arranged in parallel, an oil tank support 130, a cab support 140 and a water tank support 150, wherein the oil tank support 130, the cab support 140 and the water tank support 150 are all fixedly arranged between the first longitudinal side wall 110 and the second longitudinal side wall 120. The oil tank support 130 is used for installation of an oil tank, the cab support 140 is used for installation of a cab, and the water tank support 150 is used for installation of a water tank.
[0035] As shown in FIG.1, the road roller frame may include a first longitudinal bracket 170 located between the first longitudinal side wall 110 and the second longitudinal side wall 120. The first longitudinal bracket 170 connects the oil tank support 130 with the cab support 140. The oil tank support 130 and the cab support 140 enclose to form a hollow rectangular frame. The first longitudinal bracket 170 divides the rectangular frame into two small hollow rectangular frames, making the rectangular frame formed into a structure like the Chinese character "".
[0036] As shown in FIG.1, the cab support 140 may be constructed into an I-shaped structure. This I-shaped structure includes a first transverse bracket 141, a second transverse bracket 142, and a second longitudinal bracket 143. The first transverse bracket 141 and the second transverse bracket 142 are arranged at intervals along a longitudinal direction of the frame. Both ends of the second longitudinal bracket 143 are connected to middle portions of the first transverse bracket 141 and the second transverse bracket 142 respectively. The first transverse bracket 141 is connected to the first longitudinal side wall 110, the second longitudinal side wall 120, and the oil tank support 130. A plurality of cab mounting holes 144 are provided in the first transverse bracket 141 and the second transverse bracket 142 for installation of the cab.
[0037] As shown in FIG.1, the water tank support 150 may be located below the cab support 140. The water tank support 150 includes two sub-brackets 151 extending along the longitudinal direction of the frame, and the two sub-brackets 151 are symmetrically arranged relative to the longitudinal central plane of the frame, and with the area between the two sub-brackets 151 being hollow.
[0038] The hollowed design also helps to reduce deformation or damage caused by stress concentration resulting from uneven structural shapes, to reduce weight as much as possible while ensuring the overall structural strength of the front frame 100 of the roller, and to prolong the service life of the two longitudinal side walls.
[0039] The water tank support 150 is located at a bottom of the front frame 100, and a bottom of the water tank support 150 is provided with a tungsten carbide coating for improving the wear resistance of the front frame.
[0040] As shown in FIG.1, the road roller frame may include a hinge post 160 located between the oil tank support 130 and the water tank support 150, the hinge post 160 is used to connect with the hinging device that hingedly connects the front frame 100 to the rear frame 200.
[0041] As shown in FIG.1, the road roller frame may include a support frame 180 located between the first longitudinal side wall 110 and the second longitudinal side wall 120. The cab support 140, the water tank support 150 and the hinge post 160 are all connected to the support frame 180, and the cab support 140 is used for installation of the cab.
[0042] As shown in FIG.2, the rear frame 200 includes a third longitudinal side wall 210 and a fourth longitudinal side wall 220 arranged in parallel, a radiator support 230, a battery support 240, a power compartment support 250, and a hinge interface portion 260. The radiator support 230, the battery support 240, the power compartment support 250, and the hinge interface portion 260 are all fixedly arranged between the third longitudinal side wall 210 and the fourth longitudinal side wall 220. The radiator support 230 is used for installation of a radiator, the battery support 240 is used for installation of a power battery, and the power compartment support 250 is used for installation of a motor, an electronic control device or the like. The third longitudinal side wall 210 and the fourth longitudinal side wall 220 adopt an internally hollowed-out structure.
[0043] The hollowed-out design of the two longitudinal side walls of the rear frame helps to reduce weight as much as possible while ensuring the overall structural strength of the rear frame 200 of the road roller and also contributes to prolonging the service life of the rear frame 200 of the road roller.
[0044] As shown in FIG.2, viewed from the longitudinal side of the frame, the third longitudinal side wall 210 or the fourth longitudinal side wall 220 forms an L-shaped structure with the power compartment support 250.
[0045] Viewed from the top of the frame, the third longitudinal side wall 210, the fourth longitudinal side wall 220, the radiator support 230, and the power compartment support 250 enclose to form a hollow rectangular frame.
[0046] As shown in FIG.2, the radiator support 230 and the battery support 240 are arranged side by side along a transverse direction of the frame, and both are provided with a rectangular opening.
[0047] The hinge interface portion 260 is arranged at the longitudinal front end of the rear frame 200 for installation of the hinge device that hingedly connects the front frame 100 to the rear frame 200.
[0048] The power compartment support 250 is located at a bottom of the rear frame 200, and a bottom of the power compartment support 250 is provided with a tungsten carbide coating for improving the wear resistance of the rear frame.
[0049] The present disclosure also provides a road roller including the aforementioned road roller frame.
[0050] On the other hand, the present disclosure adopts an integrally-forming casting process, integrating more than 50 existing separate parts into a single piece. This achieves an integrated design, significantly reduces processing procedures and processing workload, and improves processing efficiency by more than 50%. This integral forming also enhances the lightweight level of the road roller frame, reducing its weight by more than 20% compared with welded frames. The entire frame has no weld seams, which improves the overall fatigue life by more than 30%, and increases the wear resistance by more than 30%.
[0051] In an another aspect of the present disclosure, a manufacturing method for the road roller frame is provided, which includes integrally forming the front frame 100 and the rear frame 200 respectively through a casting process, and then hingedly connecting the front frame 100 to the rear frame 200 together using a hinging mechanism. Owing to the adoption of the casting process, this manufacturing method helps to improve material utilization rate, and reduce the processing workload of the road roller frame, thereby conducive to shortening production time and enhancing production efficiency.First Embodiment
[0052] The present disclosure provides a manufacturing method for the road roller frame. This manufacturing method may be process methods such as the sand casting, lost foam casting, counter-gravity casting, etc. Sand casting is taken as an example to explain the casting process, and other methods may also be adopted. The casting process may include the following steps: mold-fabricating: fabricating a mold according to the model of at least one of the front frame and the rear frame. The mold may be a wooden mold, a metal mold, or a 3D-printed sand mold. Taking the 3D-printed sand mold as an example, the average diameter of the raw sand is 70 / 140 mesh, and the addition amounts of resin and curing agent are 2.0-3.0wt.% and 0.5-0.6wt.% respectively; coating-brushing: brushing coating onto a sand mold and a sand core, then drying the coated layer, inspecting the quality of the sand mold, the sand core and the coated layer, removing any coating drips and burrs, and touching up any locally defective coating areas; core-setting and flask-placing: purging floating sand from the mold cavity and vent holes, placing the sand mold and the sand core into the flask, and placing molten steel filters, risers, asbestos gaskets, etc; laying a 3-5mm thick layer of tungsten carbide particles with a diameter of 1-2mm in the sand mold in an area corresponding to the bottom of the water tank support of the front frame, wherein the tungsten carbide particle layer may be infiltrated into the bottom of the water tank during pouring of the molten steel to thereby improve wear resistance; laying a 3-5mm thick layer of tungsten carbide particles with a diameter of 1-2mm in the sand mold in an area corresponding to the bottom of the power compartment support of the rear frame, wherein the tungsten carbide particle layer may be infiltrated into the bottom of the power compartment during pouring of the molten steel, thereby to improve wear resistance; melting and pouring: placing raw materials into an electric arc furnace for melting; after melting of the raw materials, adding an appropriate amount of desulfurizers, alloying elements and so on for refining to adjust the composition of the molten steel to: C: 0.30%, Si: 0.05%, Mn: 0.70%, Nb: 0.008%, V: 0.015%, Ni: 0.6%, Cr: 0.30%, P: ≤0.020%, S: ≤0.005%, with the balance being Fe; pouring the qualified molten steel into a ladle and placing the ladle on a pouring platform while controlling the pouring temperature at 1600 °C; and pouring the molten steel through a runner tube into the sand mold, allowing the molten steel to be cooled and solidified within the mold; shakeout and part-removal: after the frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then carrying out treatments such as shot blasting, machining or the like to produce a qualified frame. A second embodiment
[0053] The present disclosure provides a manufacturing method for the road roller frame. This manufacturing method may include casting processes such as sand casting, lost foam casting or counter-gravity casting. Sand casting is taken as an example to explain the casting process, and of course, other casting processes may also be used. The casting process may include the following steps: mold-fabricating: fabricating a mold according to the model of at least one of the front frame and the rear frame. The mold can be one of a wooden mold, a metal mold and a 3D-printed sand mold, or be of other types. Take the metal mold or wooden mold as an example; core-making and core-repairing: making a sand core, removing burrs, flashes and so on from the surface of the sand core, and repairing depressions, looseness and the like on the molding surface of the sand core; coating-brushing: brushing coating onto the sand core, and then drying the coated layer, inspecting the quality of the sand core and the coated layer, removing any coating drips and burrs, and touching up any locally defective coating areas; sand molding: mixing new sand, used sand and auxiliary materials for sand molding, with the addition amount of resin being 1-2% of the total sand weight; core-setting and flask-closing: purging floating sand from the mold cavity and vent holes, placing the sand core into the flask, closing upper and lower flasks, and placing molten steel filters, risers, asbestos gaskets, etc; laying a 3-5mm thick layer of tungsten carbide particles with a diameter of 1-2mm at the bottom of the water tank support of the front frame, wherein the tungsten carbide particles may be infiltrated into the bottom of the water tank during pouring of the molten steel, thereby improving wear resistance; laying a 3-5mm thick layer of tungsten carbide particles with a diameter of 1-2mm at the bottom of the power compartment support of the rear frame, wherein the tungsten carbide particles may be infiltrated into the bottom of the power compartment during pouring of the molten steel, thus enhancing wear resistance; melting and pouring: placing raw materials into an electric arc furnace for melting; after melting of the raw materials, adding an appropriate amount of desulfurizers, alloying elements and so on for refining to adjust the composition of the molten steel to: C: 0.20%, Si: 0.1%, Mn: 0.6%, Nb : 0.005%, V: 0.010%, Ni : 0.5%, Cr: 0.20%, P : ≤0.020%, S : ≤0.005%, with the balance being Fe; pouring the qualified molten steel into a ladle, placing the ladle on a pouring platform while controlling the pouring temperature at 1620°C; and pouring the molten steel through a runner tube into the sand mold, allowing the molten steel to be cooled and solidified within the mold; shakeout and part-removal: after the frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then carrying out treatments such as shot blasting, machining or the like to produce a qualified frame. A third embodiment
[0054] The present disclosure provides a manufacturing method for the road roller frame. This manufacturing method may include sand casting, lost foam casting, counter-gravity casting, etc. Sand casting is taken as an example to explain the casting process, and of course, other casting processes may also be adopted. The casting process may include the following steps: mold-fabricating: fabricating a mold according to the model of at least one of the front frame and the rear frame. The mold can be a wooden mold, a metal mold, or a 3D-printed sand mold. Taking the 3D-printed shell mold as an example, a frame shell mold is fabricated based on 3D sand mold printing technology: the shell mold includes a pouring cup, a sprue, a runner, and a riser. The average diameter of the raw sand is 70 / 140 mesh, and the addition amounts of resin and curing agent are 5.0-6.0wt.% and 0.6-0.7wt.% respectively. coating-brushing: brushing coating onto the shell mold, and then drying the coated layer, inspecting the quality of the shell mold and the coated layer, removing any coating drips and burrs, and touching up any locally defective coating areas; placing into flask: after fitting with the shell mold, placing the sand mold in the flask; pouring a "raw sand + steel ball" mixture into the gap between the flask and the sand mold, and at the same time vibrating with a vibrating plate; after pouring, inverting the flask onto a low-pressure sealed tank, aligning the pouring cup of the shell mold with a riser tube and fixing, and laying a layer of asbestos gasket between the flask and the sealed tank; laying a 3-5mm thick layer of tungsten carbide particles with a diameter of 1-2mm at the bottom of the water tank support of the front frame, wherein the tungsten carbide particles may be infiltrated into the bottom of the water tank during pouring of the molten steel, thereby improving wear resistance; laying a 3-5mm thick layer of tungsten carbide particles with a diameter of 1-2mm at the bottom of the power compartment support of the rear frame, wherein the tungsten carbide particles may be infiltrated into the bottom of the power compartment during pouring of the molten steel, thus enhancing wear resistance; melting and pouring: placing raw materials into an electric arc furnace for melting; after melting of the raw materials, adding an appropriate amount of desulfurizers, alloying elements and so on for refining to adjust the composition of the molten steel to: C : 0.40%, Si: 0.4%, Mn: 1%, Nb: 0.03%, V: 0.030%, Ni : 1% , Cr : 0.50%, P : ≤0.020%, S : ≤0.005%, with the balance being Fe; pouring the qualified molten steel into a ladle and placing the ladle on a pouring platform while controlling the pouring temperature at 1650°C; and pouring the molten steel through a runner tube into the sand mold, allowing the molten steel to be cooled and solidified within the mold; shakeout and part-removal: after the frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then carrying out treatments such as shot blasting, machining or the like to produce a frame.
[0055] Finally, it should be explained that the above embodiments are only used to illustrate but not to limit the technical solution of the present disclosure. Although the present disclosure has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that: they can also modify the specific embodiments of the present disclosure or make equivalent replacement as for some technical features; and these modifications or replacement should be included in the scope of the technical solution claimed by the present disclosure.
Claims
1. A road roller frame, comprising: a front frame (100); and a rear frame (200) hingedly connected to the front frame (100); wherein at least one of the front frame (100) and the rear frame (200) is integrally formed by casting.
2. The road roller frame according to claim 1, wherein the front frame (100) comprises: a first longitudinal side wall (110) and a second longitudinal side wall (120) arranged in parallel; and an oil tank support (130), a cab support (140) and a water tank support (150), all of which are fixedly arranged between the first longitudinal side wall (110) and the second longitudinal side wall (120).
3. The road roller frame according to claim 2, comprising a first longitudinal bracket (170) located between the first longitudinal side wall (110) and the second longitudinal side wall (120), wherein the first longitudinal bracket (170) connects the oil tank support (130) with the cab support (140); the oil tank support (130) and the cab support (140) enclose to form a hollow rectangular frame; and the first longitudinal bracket (170) divides the rectangular frame into two hollow small rectangular frames.
4. The road roller frame according to claim 2 or 3, wherein the cab support (140) is configured in an I-shaped structure, and comprises a first transverse bracket (141), a second transverse bracket (142) and a second longitudinal bracket (143), wherein the first transverse bracket (141) and the second transverse bracket (142) are arranged at intervals along a longitudinal direction of the frame; the second longitudinal bracket (143) is connected to the first transverse bracket (141) and the second transverse bracket (142) respectively; and the first transverse bracket (141) is connected to the oil tank support (130).
5. The road roller frame according to any one of claims 2 to 4, wherein the water tank support (150) is located below the cab support (140), and comprises two sub-brackets (151) extending along the longitudinal direction of the frame, and the two sub-brackets (151) are symmetrically arranged relative to the longitudinal central plane of the frame, and an area between the two sub-brackets (151) is hollow.
6. The road roller frame according to claim 5, wherein the water tank support (150) is located at a bottom of the front frame (100), and a bottom of the water tank support (150) is provided with a tungsten carbide coating.
7. The road roller frame according to any one of claims 2 to 6, comprising a hinge post (160) located between the oil tank support (130) and the water tank support (150) for connection with a hinging device that hingedly connects the front frame (100) to the rear frame (200).
8. The road roller frame according to any one of claims 2 to 7, comprising a support frame (180) located between the first longitudinal side wall (110) and the second longitudinal side wall (120), wherein the cab support (140), the water tank support (150) and the hinge post (160) are all connected to the support frame (180).
9. The road roller frame according to any one of claims 1 to 8, wherein the rear frame (200) comprises: a third longitudinal side wall (210) and a fourth longitudinal side wall (220) arranged in parallel; and a radiator support (230), a battery support (240), a power compartment support (250) and a hinge interface portion (260), all of which are fixedly arranged between the third longitudinal side wall (210) and the fourth longitudinal side wall (220).
10. The road roller frame according to claim 9, wherein, viewed from a longitudinal side of the frame, the third longitudinal side wall (210) or the fourth longitudinal side wall (220) forms an L-shaped structure with the power compartment support (250).
11. The road roller frame according to claim 9 or 10, wherein, viewed from a top of the frame, the third longitudinal side wall (210), the fourth longitudinal side wall (220), the radiator support (230) and the power compartment support (250) enclose to form a hollow rectangular frame.
12. The road roller frame according to any one of claims 9 to11, wherein the radiator support (230) and the battery support (240) are arranged side by side along a transverse direction of the frame, and both are provided with a rectangular opening.
13. The road roller frame according to any one of claims 9 to 12, wherein the hinge interface portion (260) is disposed at a longitudinal front end of the rear frame (200) for installation of a hinge device that hingedly connects the front frame (100) to the rear frame (200).
14. The road roller frame according to any one of claims 9 to 13, wherein the power compartment support (250) is located at a bottom of the rear frame (200), and a bottom of the power compartment support (250) is provided with a tungsten carbide coating.
15. A road roller, comprising the road roller frame according to any one of claims 1 to 14.
16. A manufacturing method for the road roller frame according to any one of claims 1 to 14, comprising: integrally forming at least one of the front frame (100) and the rear frame (200) by a casting process; and hingedly connecting the front frame (100) to the rear frame (200).
17. The manufacturing method according to claim 16, wherein the casting process is one of sand casting, lost foam casting and counter-gravity casting.
18. The manufacturing method according to claim 16, wherein the casting process comprises the following steps: mold-fabricating: fabricating a mold according to a model of at least one of the front frame and the rear frame. coating-brushing: brushing coating onto a sand mold and a sand core, and then drying a coated layer, core-setting and flask-placing: putting the sand mold and the sand core into a flask, and laying tungsten carbide particles in the sand mold in an area corresponding to a water tank support of the front frame or in an area corresponding to a bottom of a power compartment support of the rear frame; melting and pouring: melting raw materials into a liquid state, and pouring the raw materials into the sand mold, wherein a composition of the raw materials is as follows: C: 0.30%, Si: 0.05%, Mn: 0.70%, Nb: 0.008%, V: 0.015%, Ni: 0.6%, Cr: 0.30%, P: ≤0.020%, S: ≤0.005%, and the balance is Fe; and shakeout and part-removal: after a frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then carrying out treatments such as shot blasting, machining or the like to produce a qualified frame sample.
19. The manufacturing method according to claim 16, wherein the casting process comprises the following steps: mold-fabricating: fabricating a mold according to a model of at least one of the front frame and / or the rear frame; core-making and core-repairing: making a sand core and repairing the sand core; coating-brushing: brushing coating onto the sand core, and then drying a coated layer; sand molding: mixing new sand, used sand and auxiliary materials for sand molding, with an addition amount of resin being 1-2% of the total sand weight; core-setting and flask-closing: putting the sand core into a flask, closing upper and lower flasks, and laying tungsten carbide particles in a sand mold in an area corresponding to a water tank support of the front frame or in an area corresponding to the bottom of a power compartment support of the rear frame; melting and pouring: melting raw materials, a composition of which is as follows: C: 0.20%, Si: 0.1%, Mn: 0.6%, Nb: 0.005%, V: 0.010%, Ni: 0.5%, Cr: 0.20%, P: ≤0.020%, S: ≤0.005%, and the balance is Fe; and pouring the raw materials into the sand mold, allowing it to be cooled and solidified in the mold, wherein the pouring temperature is controlled at 1620°C; and shakeout and part-removal: after a frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then shot-blasting and machining to obtain the front frame and / or the rear frame.
20. The manufacturing method according to claim 16, wherein the casting process comprises the following steps: mold-fabricating: fabricating a mold according to a model of at least one of the front frame and / or the rear frame; coating-brushing: brushing coating onto a shell mold, and then drying a coated layer; placing into flask: placing a sand mold in a flask, pouring a mixture of raw sand and steel balls into the gap between the flask and the sand mold and meanwhile vibrating with a vibrating plate; and laying tungsten carbide particles in the sand mold in an area corresponding to the water tank support of the front frame or in an area corresponding to a bottom of the power compartment support of the rear frame; melting and pouring: melting raw materials, a composition of which is as follows: C: 0.40%, Si : 0.4%, Mn : 1%, Nb : 0.03%, V : 0.030%, Ni : 1%, Cr : 0.50%, P : ≤0.020%, S : ≤0.005%, and the balance is Fe; pouring the raw materials into the sand mold, allowing it to be cooled and solidified in the mold, wherein the pouring temperature is controlled at 1650°C; and shakeout and part-removal: after a frame cast blank has been solidified, opening the flask to take out the frame cast blank and letting it stand for air cooling; subjecting the fully-cooled frame cast blank to heat treatment, and then shot-blasting and machining to obtain the front frame and / or the rear frame.