Suction nozzle and method for manufacturing the same

Abstract

To provide a method for manufacturing a suction nozzle with improved recovery efficiency for flux.SOLUTION: A method for manufacturing a suction nozzle manufactures a suction nozzle which is used for recovering flux covering slag 200 formed on a weld bead 300 after submerged arc welding, and has a suction port for sucking up the flux. The method includes the steps of: preparing a base material 1000 on which the weld bead 300 and the slag 200 are formed; preparing a notch portion precursor 90 that becomes a notch portion located at the tip of the suction port; deforming the notch portion precursor 90; and heating the deformed notch portion precursor 90 to form the notch portion. During deformation of the notch portion precursor 90, the notch portion precursor 90 is pressed against the outer surface 200a of the slag 200 formed on the base material 1000, and is deformed to have a shape along the outer surface 200a.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a suction nozzle and a method for manufacturing the same.

Background Art

[0002] Conventionally, a flux recovery device used for recovering a flux covering slag formed on a weld bead after performing submerged arc welding on a base material has become widespread. When recovering the flux by this flux recovery device, while applying the tip of the suction port of the suction nozzle of the flux recovery device to the convex outer surface of the slag, the suction nozzle is moved along the extending direction of the weld bead. Thereby, the flux covering the slag can be sequentially sucked from the suction port. As a document disclosing this type of suction nozzle and a flux recovery device provided with the same, for example, there is Japanese Utility Model Laid-Open No. 60-11174 (Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Here, from the viewpoint of improving the recovery efficiency of the flux by the suction nozzle, it is desirable not to create a gap between the tip of the suction port of the suction nozzle and the convex outer surface of the slag. However, the outer surface of this slag varies in size depending on various welding conditions such as the heat input amount of welding and the groove dimension of the base material. Therefore, it is not easy to suppress the occurrence of a gap between the tip of the suction port of the suction nozzle manufactured as a standard product and the outer surface of the slag.

[0005] Accordingly, the present invention has been made in view of the above points, and an object thereof is to provide a suction nozzle in which the recovery efficiency of the flux is improved and a method for manufacturing the same.

Means for Solving the Problems

[0006] The method for manufacturing a suction nozzle according to the present invention is used for recovering the flux covering the slag formed on the weld bead after submerged arc welding, and a suction nozzle having a suction port for sucking the flux is manufactured. The method includes preparing a base material on which the weld bead and the slag are formed, preparing a notch precursor that becomes a notch portion located at the tip of the suction port, deforming the notch precursor, and forming the notch portion by heating the deformed notch precursor. In the method for manufacturing a suction nozzle according to the present invention, when the notch precursor is deformed, the notch precursor is pressed against the convex outer surface of the slag formed on the base material, and the notch precursor is deformed so as to have a shape along the outer surface.

[0007] By manufacturing in this way, it becomes possible to customize the notch portion so as to have the same shape as the shape of the outer surface of the slag formed under predetermined welding conditions. As a result, it becomes possible to effectively reduce the gap between the notch portion located at the tip of the suction nozzle and the outer surface of the slag. Therefore, it is possible to manufacture a suction nozzle with improved flux recovery efficiency.

[0008] In the method for manufacturing a suction nozzle according to the present invention, when the notch precursor is deformed, the notch precursor is deformed so as to have a shape along the outer surface while being heated by the residual heat of the slag.

[0009] By manufacturing in this way, it becomes unnecessary to prepare an external heat source to cure the notch precursor. Therefore, not only can the manufacturing cost of the suction nozzle including the notch be reduced, but also the manufacturing equipment can be simplified.

[0010] In the method for manufacturing a suction nozzle according to the present invention, the notch precursor is made of a thermosetting resin.

[0011] By manufacturing in this way, it is possible to manufacture a suction nozzle including a notch excellent in heat resistance, moldability, mechanical strength, and the like.

[0012] The suction nozzle according to the present invention is used for recovering a flux covering slag formed on a weld bead after submerged arc welding, and includes a suction port for sucking the flux and a base portion connected to a root side portion of the suction port. The suction port has a notch at its tip having a shape along the convex outer surface of the slag. In the suction nozzle according to the present invention, the notch is made of a material different from that of the base portion.

[0013] By configuring in this way, it is possible to give the notch different material characteristics from those of the base portion. Further, the notch can be manufactured by a manufacturing method different from that of the base portion.

[0014] In the suction nozzle according to the present invention, the notch is made of a thermosetting resin.

[0015] By configuring in this way, it is possible to obtain a suction nozzle including a notch excellent in heat resistance, moldability, mechanical strength, and the like.

Advantages of the Invention

[0016] According to the present invention, it is possible to provide a suction nozzle and a method for manufacturing the same in which the flux recovery efficiency is improved.

Brief Description of the Drawings

[0017]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

BEST MODE FOR CARRYING OUT THE INVENTION

[0018] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the embodiments shown below, the same or common parts are denoted by the same reference numerals in the drawings, and the description thereof will not be repeated.

[0019] (Embodiment) FIG. 1 is a perspective view of a flux recovery device including a suction nozzle according to an embodiment. FIGS. 2(A) and 2(B) are a side view and a front view, respectively, in which the vicinity of the head portion of the suction nozzle shown in FIG. 1 is enlarged. FIG. 3(A) is a schematic perspective view for explaining a state of recovering flux using the flux recovery device shown in FIG. 1. FIG. 3(B) is a schematic side view of the suction nozzle and the like as viewed from the direction of arrow IIIB shown in FIG. 3(A). First, with reference to FIGS. 1 to 3, a flux recovery device 1 including a suction nozzle 10 according to the present embodiment will be described.

[0020] In FIG. 2(B), for easy understanding, the first member constituting the notch portion 31b described later is provided with dense dot hatching, and the second member constituting the head portion 30 of the portion other than the notch portion 31b is provided with sparse dot hatching.

[0021] As shown in FIGS. 1 to 3, the flux recovery device 1 recovers the flux 100 that covers the slag 200 formed on the weld bead 300 (see FIGS. 5 and the like described later) after the submerged arc welding of the base material 1000.

[0022] The flux recovery device 1 includes a suction nozzle 10, a main body portion 50, and a gantry 60. The suction nozzle 10 is provided with a suction port for sucking the flux 100. The main body portion 50 accommodates the flux 100 sucked from the suction nozzle 10.

[0023] The root portion of the suction nozzle 10 is connected to the side wall of the main body portion 50. The main body portion 50 is fixed to the gantry 60. Casters are attached to the gantry 60. Thereby, the suction nozzle 10 and the main body portion 50 are configured to be movable.

[0024] A negative pressure source (not shown) is connected to the main body portion 50. For example, a ring blower is used as the negative pressure source.

[0025] The suction nozzle 10 is provided with a suction path 10b for sucking the flux 100 toward the accommodation space of the main body portion 50. The suction nozzle 10 includes a flexible hose portion 20 and a hollow head portion 30 attached to the tip of the hose portion 20.

[0026] As shown in FIGS. 2(A) and 2(B), the head portion 30 has an outer shape with a tapered shape that increases in size in the width direction (the left-right direction in FIG. 2(B)) from the base side toward the tip side. The head portion 30 includes a chip portion 31 that is a tip-side portion, and a base portion 32 having one end connected to the base-side portion of the chip portion 31 and the other end connected to the hose portion 20. In the present embodiment, the chip portion 31 corresponds to the suction port of the suction nozzle 10.

[0027] The end face 31a of the chip portion 31 extends in a first direction D1 that is orthogonal to the axial direction D0 of the suction nozzle 10. The end face 31a of the chip portion 31 is inclined so as to intersect obliquely with respect to the axial direction D0 when viewed from the first direction D1 (see particularly FIG. 2(A)).

[0028] As a result, when the operator grips the suction nozzle 10, the operator can grip the suction nozzle 10 in a state where it is inclined more than the state where it stands upright along the vertical direction (that is, a state where it is laid down more than the upright state) by the amount that the end face 31a of the chip portion 31 is inclined as described above (see FIG. 3(B)). Therefore, the operator can grip the suction nozzle 10 in a more comfortable posture.

[0029] The head portion 30 is detachably attached to the hose portion 20. As an example, in the present embodiment, a hose nipple (not shown) is fixed to the end portion of the hose portion 20 on the head portion 30 side using a hose band 70. By screwing the male thread of this hose nipple with the female thread provided at the end portion of the base portion 32 on the hose portion 20 side, the head portion 30 including the base portion 32 is detachably attached to the hose portion 20. Note that the method of detachably attaching the head portion 30 to the hose portion 20 is not limited to the method described above and can be changed as appropriate.

[0030] The space inside the head portion 30 communicates with the space inside the hose portion 20. These internal spaces define the suction path 10b of the suction nozzle 10. One end of the suction path 10b is connected to the accommodation space of the main body portion 50. The other end of the suction path 10b opens at the tip of the chip portion 31. When the negative pressure source described above is driven to generate a negative pressure in the suction path 10b, the flux 100 is sucked toward the accommodation space of the main body portion 50 via the suction path 10b.

[0031] The hose portion 20 is made of a flexible material such as rubber, for example. The head portion 30 is made of a plurality of different materials. The materials constituting the head portion 30 will be described in detail later.

[0032] As shown in FIG. 2(B), a notch portion 31b is provided at the tip of the chip portion 31. More specifically, the notch portion 31b is provided in each of the front side portion (i.e., the front side of the paper in FIG. 2(B)) and the back side portion (i.e., the back side of the paper in FIG. 2(B)) of the tip of the chip portion 31. In the following, only the notch portion 31b provided in the front side portion of these pair of notch portions 31b will be described, and the description of the notch portion 31b provided in the back side portion will not be repeated. This is because the configuration of the notch portion 31b provided in the back side portion is the same as the configuration of the notch portion 31b located on the front side.

[0033] The notch portion 31b is located at the center of the end face 31a of the chip portion 31 in the first direction D1. The notch portion 31b has a substantially semicircular shape when viewed from the second direction D2 that is orthogonal to both the axial direction D0 and the first direction D1.

[0034] The notch portion 31b has a shape along the outer surface 200a of the slag 200. More specifically, the notch portion 31b is configured such that its shape is the same as the shape of the outer surface 200a of the slag 200 formed under predetermined welding conditions. Thereby, it becomes possible to effectively reduce the gap between the tip of the chip portion 31 and the outer surface 200a of the slag 200. A manufacturing method of the notch portion 31b configured as described above will be described in detail later.

[0035] The notch portion 31b is constituted by a first member made of a material different from that of the head portion 30 of the portion other than the notch portion 31b (that is, the chip portion 31 and the base portion 32 of the portion other than the notch portion 31b).

[0036] In the present embodiment, the first member is constituted by a phenolic resin which is a thermosetting resin. Thereby, the notch portion 31b can be made excellent in heat resistance, moldability, mechanical strength, and the like. Further, the second member constituting the head portion 30 of the portion other than the notch portion 31b is constituted by aluminum.

[0037] The first member is connected to the second member by, for example, adhesion or the like. In this case, the adhesion strength may be improved by performing embossing on the portion of the surface of the first member facing the second member and / or the portion of the surface of the second member facing the first member.

[0038] Note that the connection method of the first member to the second member is not particularly limited to adhesion and can be variously changed. For example, the first member may be connected to the second member by the magnetic force of a magnet sheet attached to the portion of the surface of the first member facing the second member and the portion of the surface of the second member facing the first member. Alternatively, by providing a fitting-shaped portion on the portion of the first member facing the second member and / or the portion of the second member facing the first member, these may be connected by fitting.

[0039] When recovering the flux 100 using the flux recovery device 1 configured as described above, first, the ring blower serving as a negative pressure source connected to the main body 50 is driven. As a result, a negative pressure is generated in the suction path 10b, and the suction of the flux 100 is started.

[0040] Next, as shown in FIGS. 3(A) and 3(B), the tip of the chip portion 31 is applied to the convex outer surface 200a of the slag 200. More specifically, the notch portion 31b of the chip portion 31 is applied to the outer surface 200a of the slag 200 so that no gap is formed between the tip of the chip portion 31 and the outer surface 200a of the slag 200.

[0041] Next, while the tip of the chip portion 31 is applied to the outer surface 200a of the slag 200, the suction nozzle 10 is moved along the extending direction of the weld bead 300 (see the arrow AR1 in FIG. 3(A)). As a result, the flux 100 distributed along the extending direction is sequentially sucked.

[0042] FIG. 4 is a flowchart showing a method for manufacturing the suction nozzle according to the present embodiment. FIGS. 5 to 7 are schematic cross-sectional views showing the method for manufacturing the suction nozzle according to the present embodiment. Next, with reference to FIGS. 4 to 7, the method for manufacturing the suction nozzle 10 according to the present embodiment will be specifically described.

[0043] Here, FIG. 5 is a diagram showing a cross section of the base material 1000, the slag 200, and the weld bead 300 at a position corresponding to the V-V line in FIG. 3(A), and the mold 500 and the notch precursor 90 to be described later (the same applies to FIGS. 6 and 7).

[0044] As shown in FIG. 4, in the method for manufacturing the suction nozzle 10 according to the present embodiment, first, in step S1, the hose portion 20 and the second member that is a member constituting the head portion 30 other than the notch portion 31b are prepared. The hose portion 20 and the second member may be connected to each other via the above-described hose nipple as necessary.

[0045] Next, as shown in FIG. 4, in step S2, the base material 1000 after submerged arc welding is prepared. The base material 1000 is provided with a weld bead 300 and a slag 200 formed on the weld bead 300. In the base material 1000 after submerged arc welding, the flux 100 covers the slag 200, while in the base material 1000 prepared in step S2, the slag 200 is exposed by removing the flux 100.

[0046] Next, as shown in FIG. 4, in step S3, the notch precursor 90 is prepared. The notch precursor 90 is a member that will become the notch 31b through steps S4 to S6, which will be described in detail later. In the present embodiment, the notch precursor 90 is made of a phenolic resin, which is a thermosetting resin.

[0047] Next, as shown in FIGS. 4 and 5, in step S4, the notch precursor 90 is set in the mold 500. More specifically, the mold 500 is filled with the notch precursor 90 in a state where it has fluidity by being heated in a water bath or the like as necessary.

[0048] Next, as shown in FIGS. 4 and 6, in step S5, the notch precursor 90 is pressed against the slag 200 by the mold 500. More specifically, the mold 500 filled with the notch precursor 90 in a state of having fluidity is moved toward the slag 200 formed on the base material 1000 (see arrow AR2 in FIG. 6). As a result, the notch precursor 90 is pressed against the outer surface 200a of the slag 200. Consequently, the notch precursor 90 is deformed so that a concave portion having a shape along the outer surface 200a of the slag 200 is provided on its surface.

[0049] Here, as shown in FIG. 6, in the present embodiment, from the viewpoint of preventing the notch precursor 90 in a fluid state from spilling out of the mold 500 when it is pressed against the slag 200, the notch precursor 90 is pressed against the slag 200 provided on the base material 1000 disposed above the mold 500 from below upward. However, when the notch precursor 90 has a considerable viscosity or the like, and the probability of the notch precursor 90 spilling out as described above is low, it is not always necessary for the notch precursor 90 to be pressed against the slag 200 from below upward.

[0050] Next, as shown in FIG. 4, in step S6, the notch precursor 90 is heated. More specifically, the notch precursor 90 provided with recesses on its surface in step S5 is heated by the residual heat of the slag 200. That is, in the present embodiment, the notch precursor 90 is deformed while being heated by the residual heat of the slag 200 so as to have a shape along the outer surface 200a of the slag 200.

[0051] The notch precursor 90 is cured by being heated. The notch precursor 90 cured in this way becomes a notch portion 31b (that is, the first member described above) configured to have the same shape as the shape of the outer surface 200a of the slag 200 as described above.

[0052] When the slag 200 is sufficiently cooled, the notch precursor 90 may be heated using an external heat source such as a heater.

[0053] Next, as shown in FIGS. 4 and 7, in step S7, the pressing of the notch portion 31b against the slag 200 by the mold 500 is released. More specifically, the mold 500 containing the notch portion 31b is moved in a direction away from the base material 1000 (see arrow AR3 in FIG. 7).

[0054] Next, as shown in FIG. 4, in step S8, the notch portion 31b is cooled. The method of cooling the notch portion 31b is not particularly limited. The notch portion 31b may be forcibly cooled by blowing cooling air onto it, or may be naturally cooled by leaving the notch portion 31b in a room-temperature space.

[0055] Next, as shown in FIG. 4, in step S9, the notch portion 31b is connected to the second member. The notch portion 31b is connected to the second member, for example, by using an adhesive.

[0056] By going through steps S1 to S9 described above, the suction nozzle 10 according to the above-described embodiment is manufactured.

[0057] Note that the manufacturing method of the suction nozzle 10 according to the above-described embodiment is merely an example, and the order and the like can be appropriately changed.

[0058] Also, in the manufacturing method of the suction nozzle 10 according to the above-described embodiment, in step S6, the case where the notch precursor 90 is heated by the waste heat of the slag 200 is illustrated and described. However, the notch precursor 90 does not necessarily have to be heated by the waste heat of the slag 200, and may be heated by an external heat source such as a heater. Further, when heating the notch precursor 90 by an external heat source, the notch precursor 90 may be directly heated by the heat source, or the notch precursor 90 may be indirectly heated through the mold 500 heated by the heat source.

[0059] Here, the outer surface 200a of the slag 200 will have different sizes depending on various welding conditions. Therefore, when recovering the flux 100 using a suction nozzle manufactured as a standard product, due to the difference between the size of the notch provided at the tip of the suction nozzle and the size of the outer surface 200a of the slag 200, a large gap will be generated between the tip of the suction nozzle and the outer surface 200a of the slag 200, resulting in a significant reduction in the recovery efficiency of the flux 100.

[0060] In this regard, in the manufacturing method of the suction nozzle 10 according to the present embodiment, as described above, the notch precursor 90 is deformed to have a shape along the outer surface 200a by being pressed against the outer surface 200a of the slag 200, and the notch 31b is formed by heating and curing the notch precursor 90 in this state.

[0061] By manufacturing in this way, it becomes possible to customize the notch 31b to have the same shape as the shape of the outer surface 200a of the slag 200 formed under predetermined welding conditions. As a result, it becomes possible to effectively reduce the gap between the notch 31b located at the tip of the suction nozzle 10 and the outer surface 200a of the slag 200.

[0062] Therefore, by manufacturing according to the manufacturing method of the suction nozzle 10 according to the present embodiment, it is possible to obtain a suction nozzle with improved flux recovery efficiency.

[0063] Also, in the manufacturing method of the suction nozzle 10 according to the present embodiment, as described above, the notch precursor 90 is deformed to have a shape along the outer surface 200a while being heated by the residual heat of the slag 200.

[0064] By manufacturing in this way, there is no need to prepare an external heat source to cure the notch precursor 90. Therefore, not only can the manufacturing cost of the suction nozzle 10 including the notch 31b be reduced, but also the manufacturing equipment can be simplified.

[0065] (Modification example) FIG. 8 is an enlarged front view of the vicinity of the head portion of the suction nozzle according to the modification example. Hereinafter, with reference to FIG. 8, the suction nozzle 10A according to the modification example based on the above-described embodiment will be described. In FIG. 8, for ease of understanding, the third member described later that constitutes the chip portion 31 including the notch 31b is hatched with dense dots, and the fourth member that constitutes the base portion 32 is hatched with sparse dots.

[0066] As shown in FIG. 8, the suction nozzle 10A according to this modification example has a different configuration of the head portion 30A when compared with the suction nozzle 10 according to the above-described embodiment.

[0067] More specifically, in the head portion 30A, the chip portion 31 including the notch 31b is constituted by a third member. The third member defines all of the opening of the suction nozzle 10A, unlike the first member that defines a part of the opening of the suction nozzle 10. The third member is constituted by, for example, a phenolic resin which is a thermosetting resin.

[0068] Also, in the head portion 30A, the base portion 32 is constituted by a fourth member made of a material different from that of the third member. The fourth member is constituted by, for example, aluminum.

[0069] The manufacturing method of the suction nozzle 10A configured in this way can be manufactured by a method similar to the manufacturing method of the suction nozzle 10 described in the above-described embodiment. More specifically, the third member can be manufactured by a method similar to the method of manufacturing the notch 31b in the manufacturing method of the suction nozzle 10.

[0070] Even when configured in this way, the same effects as those described in the above-described embodiments can be obtained, and the suction nozzle can be made to improve the recovery efficiency of the flux.

[0071] (Other forms, etc.) In the embodiments and their modifications described above, the shapes, configurations, sizes, numbers, materials, etc. of the respective parts shown can be variously changed as long as they do not depart from the gist of the present invention.

[0072] Also, the characteristic configurations shown in the above-described embodiments and their modifications of the present invention can be naturally combined with each other within the scope not departing from the gist of the present invention.

[0073] Thus, the above-described embodiments and their modifications disclosed this time are illustrative in all respects and not restrictive. The technical scope of the present invention is defined by the scope of the claims, and includes all modifications within the meaning and scope equivalent to the description of the scope of the claims.

Explanation of Reference Numerals

[0074] 10, 10A Suction nozzle, 31b Notch, 32 Base portion, 90 Notch precursor, 100 Flux, 200 Slag, 200a Outer surface, 300 Weld bead, 1000 Base material.

Claims

1. A method for manufacturing a suction nozzle used for recovering a flux covering slag formed on a weld bead after submerged arc welding, the suction nozzle having a suction port for sucking the flux, comprising: preparing a base material on which the weld bead and the slag are formed; preparing a notch precursor that becomes a notch portion located at the tip of the suction port; deforming the notch precursor; forming the notch portion by heating the deformed notch precursor, and in deforming the notch precursor, the notch precursor is deformed to have a shape along the convex outer surface of the slag by being pressed against the convex outer surface of the slag formed on the base material. A method for manufacturing a suction nozzle.

2. The method for manufacturing a suction nozzle according to claim 1, wherein in deforming the notch precursor, the notch precursor is deformed to have a shape along the outer surface while being heated by the residual heat of the slag.

3. The method for manufacturing a suction nozzle according to claim 1 or 2, wherein the notch precursor is made of a thermosetting resin.

4. A suction nozzle used for recovering a flux covering slag formed on a weld bead after submerged arc welding, comprising: a suction port for sucking the flux; and a base portion connected to the root side portion of the suction port, wherein the suction port has a notch portion at its tip having a shape along the convex outer surface of the slag, and the notch portion is made of a material different from that of the base portion. A suction nozzle.

5. The suction nozzle according to claim 4, wherein the notch portion is made of a thermosetting resin.

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