CN215238459U - Cracked welding device for base of large wheel fixing table - Google Patents

Abstract

The utility model discloses a welding device for the base fracture of a large wheel fixing table, which comprises a structural member frame and heating devices respectively arranged at the front side and the rear side in the structural member frame; the bottom of the structural member frame is provided with an upper and lower levelness adjusting device, the left and right sides of the structural member frame are provided with left and right assembly fixing devices, and the front and rear sides of the structural member frame are provided with front and rear assembly fixing devices; and a horizontal adjusting plate is also arranged on the upper and lower levelness adjusting devices. The utility model also discloses a prosthetic technology of this cracked welding set of large-scale wheel fixed station base. Welding set can provide effectual guarantee for the fixed station base when the welding, avoids the welding process deflection too big, cooperates this repair technology, and not only safe easy operation, welding quality is stable, the investment cost is lower, has satisfied on-the-spot actual demand, and work efficiency is high, moreover greatly reduced cost of maintenance, reduced long-time process and shut down the loss, produce all kinds of wheels and provide the guarantee for reasonable group's production.

Description

Cracked welding device for base of large wheel fixing table

Technical Field

The utility model belongs to the technical field of the welding, a cracked welding set of large-scale wheel fixed station base and repair technology is related to.

Background

The technology limited company of the rail transit material of the horse steel is an important train wheel production base in China, is the biggest wheel production enterprise in Asia, is the only enterprise capable of producing the wheels of passenger cars with the speed grade of more than 120Km/h in China, and the research and development of heavy-duty wheels reach the international advanced level. At present, two wheel production lines are provided, and the annual production capacity is 80 ten thousands. A production line of the special goods-supplying wheel is provided, and the wheel core rolling process flow is as follows: heating a steel blank, removing phosphorus on the whole surface, preforming 60MN wheels, rolling by a rolling mill, clamping by a movable manipulator, and positioning and forming by 31.5 MN. Working principle of 60MN wheel preforming rolling mill: the dephosphorized hot steel blank is placed on an upper grinding tool and a lower grinding tool and is pressed up and down, the upper die is connected and fixed above a rolling mill and is fastened with a movable beam, the lower die is installed on a base of a large wheel fixing table which is designed and manufactured, and the base of the large wheel fixing table is installed on the base surface of an oil press and bears rolling pressure and the weight of an equipment body. Due to the fact that the oil press is unstable and the base surface contacted with the bottom of the fixed table base is abraded for a long time, the base of the large wheel fixed table is broken, and rolling accuracy of the wheel is seriously affected. If a new large-scale wheel fixed station base is replaced, not only the cost of million spare parts is needed, but also the period for purchasing and processing new spare parts is long due to no spare parts, and the production is influenced. In order to recover production as soon as possible, the large wheel fixed station base needs to be welded and repaired so as to ensure that the cracked large wheel fixed station base can be reused economically, safely and reliably, but no precedent for welding and repairing similar equipment exists at present. In addition, the main difficulty of welding repair of the large wheel fixed station base is that after the welding repair of the cracking part of the base to be fixed is completed, the base of the whole fixed station is ensured not to generate structural deformation, the arrangement of various rolling dies, the deformation of components during the expansion and contraction of rolled red steel and various substandard performances of internal tissues are not influenced, and the surface of the base cannot have any welding defects so as to avoid the subsequent influence on the service cycle quality of the large wheel fixed station base.

SUMMERY OF THE UTILITY MODEL

The characteristics to the cracked welding nature of large-scale wheel fixed station base in the background art, the utility model provides a cracked welding set of large-scale wheel fixed station base and repair technology are implemented and are verified through the welding, the utility model discloses can implement fast and accomplish large-scale wheel fixed station base fracture welding repair, reduce purchasing cost, reduce long-time process and shut down the loss, produce various domestic and foreign wheels for reasonable group and provide the guarantee.

The utility model provides a technical problem's technical scheme as follows:

the utility model relates to a welding device for the base fracture of a large wheel fixing table, which comprises a structural member frame and heating devices respectively arranged at the front side and the rear side in the structural member frame; the bottom of the structural member frame is provided with an upper and lower levelness adjusting device, the left and right sides of the structural member frame are provided with left and right assembly fixing devices, and the front and rear sides of the structural member frame are provided with front and rear assembly fixing devices; and a horizontal adjusting plate is also arranged on the upper and lower levelness adjusting devices.

Furthermore, the structural member frame comprises a bottom plate, a plurality of support legs uniformly distributed at the bottom of the bottom plate and two frame units symmetrically arranged at the top of the bottom plate at intervals.

Furthermore, the upper and lower levelness adjusting device comprises a plurality of upper and lower adjusting screw rods which are uniformly arranged on the bottom plate in a penetrating way; the left and right pairing and fixing device comprises a plurality of left and right adjusting screw rods which are respectively arranged on the outer sides of the left and right frame units in a penetrating manner; the front and rear group is to fixing device including evenly running through a plurality of front and rear adjusting screw that set up on every frame element front and rear side.

Furthermore, the heating device is a gas heating device and comprises a gas access pipe, a gas main pipe is arranged on the gas access pipe, a plurality of gas branch pipes are vertically communicated with the gas main pipe, and a plurality of nozzles are uniformly arranged on each gas branch pipe.

Furthermore, the coal gas access pipe is also provided with a regulating valve.

Furthermore, a plurality of triangular reinforcing steel plates are uniformly welded between each support leg and the bottom plate; a plurality of triangular reinforcing steel plates are uniformly welded between the outer side of the frame unit and the bottom plate.

The utility model provides a technical problem's another technical scheme as follows:

based on the technical scheme, the repair process of the welding device for the base fracture of the large wheel fixing table comprises the following steps:

firstly, welding pretreatment of a fixed table base; firstly, respectively arranging a first bevel face and a second bevel face at the fracture part of a fixed table base, then inserting the fixed table base into horizontal adjusting plates in two frame units of a structural member frame, assembling the first bevel face and the second bevel face at the fracture part of the fixed table base to form an X-shaped groove, adjusting the horizontal adjusting plates through upper and lower adjusting screws to control the levelness of the fixed table base after assembling, controlling the left and right positions and the front and rear positions of the fixed table base after assembling to accord with the mounting process dimension through left and right adjusting screws and front and rear adjusting screws respectively, locking and fixing, and finally connecting and fixing a heating device on two sides of the X-shaped groove of the fixed table base;

step two, welding preparation;

2.1), welding equipment: HT400D digital control inversion type manual direct current argon arc welding machine, wherein welding materials are ER-50-6 welding wires, the purity of argon is more than or equal to 99.99%, Nb-500P digital pulse gas shielded welding is carried out, direct current positive connection is carried out, the welding materials are SWE71.1 flux-cored welding wires, and the purity of carbon dioxide gas is more than or equal to 99.8%;

2.2), oil stains, oxide layers, moisture and the like do not exist in a welding position area and a welding wire, and the metallic luster needs to be exposed;

2.3), welding technical requirements: the overlaying layer fuses base materials, and a welding seam cannot have any welding defects;

2.4), weldment material: z35 #;

2.5), auxiliary facilities: the device comprises a heat-insulating barrel, a sample plate, a temperature measuring instrument, a magnifier, a mask, gloves, a slag removing hammer, a chisel, a file, a steel brush, abrasive paper, a steel ruler, a horizontal ruler, a movable spanner, a straight grinder, an angle grinder, a wire pliers, a steel saw blade and labor protection articles;

2.6) setting welding process parameters according to welding equipment, weldment materials and welding materials;

step three, welding and repairing;

3.1) because the groove formed at the fracture part of the fixed table base is a double-sided symmetrical X-shaped groove and is thicker, the two sides of the fixed table base are uniformly preheated by the heating device at the same time and reach the preheating temperature;

3.2) simultaneously and symmetrically welding the priming layer on two sides of the X-shaped groove by adopting ER-50-6 welding wires through two argon arc welding machines, adding the welding wires to continuously perform arc extinguishing welding from bottom to top when the groove on one side is welded, enabling the welding gun to vertically form an included angle of 50-70 degrees with the groove, enabling a vertical inclination angle on the welding wires to be 20-40 degrees, not adding the welding wires into the welding machine on the other side, adopting self-fluxing priming welding, enabling the current to be larger than 15% of that of normal priming welding, and fusing the root of the priming on the back surface through to ensure that no welding defect exists;

3.3) after welding of the bottom layer is finished and no welding defect is detected, welding a filling layer from bottom to top symmetrically by two carbon dioxide gas shielded welding machines by using a SWE71.1 flux-cored wire, wherein the filling layer adopts multilayer and multi-pass welding according to the width of a groove, and after each layer needs visual inspection and a magnifying glass of 5 times to detect no welding defect of a welding line, the next layer is welded;

3.4) after the welding of the filling layer is finished and no welding defect is detected, the covering layer is welded from bottom to top by two carbon dioxide gas shielded welding machines simultaneously and symmetrically by using SWE71.1 flux-cored wires, the covering layer is welded in multiple layers and multiple channels according to the width of a groove, the interlayer temperature is kept at 200-250 ℃, a welding gun vertically forms an angle of 80-90 degrees with the groove, a crescent operation method is adopted, each layer needs to be detected by visual inspection and a 5-time magnifier to detect that no welding defect exists in a welding seam, then the next layer is welded, particularly, the welding seam of the covering layer is higher than the base metal and smoothly transits with the two sides of the base metal, after all welding of the through cracks are finished, the covering layer is cooled to room temperature and then is subjected to all-directional detection instrument flaw detection welding detection and detection;

3.5), confirm not having any welding defect after, both sides welder takes away simultaneously, restart heating device continues to carry out the even intensification to whole fixed station base and heats to 600 ~ 650 ℃ and constant temperature 4 hours, then slowly falls to 250, adopts asbestos to wrap slowly and cools off till the room temperature again, processes to accord with the use size to the fixed station base that the welding was accomplished through the mechanical grinding at last to accord with the technological requirement through detecting, deliver the use.

Furthermore, the bottom layer adopts an ER-50-6 welding wire with the diameter of phi 2.5mm, the welding current is 90-130A, the arc voltage is 17 +/-1V, and the welding speed is 5 +/-1 cm/min; the filling layer adopts SWE71.1 flux-cored wire with phi of 1.2mm, the welding current is 280-320A, the arc voltage is 28-32V, and the welding speed is 90-140 g/min; the covering surface layer adopts SWE71.1 flux-cored wire with phi of 1.2mm, the welding current is 180-220A, the arc voltage is 23-25V, and the welding speed is 70 g/min.

Further, the heating device uniformly preheats the two sides of the base of the fixed station at the same time and reaches the preheating temperature of 250 ℃ to 300 ℃, and the temperature rising speed is 50 ℃/h during preheating; after the cover surface layer is welded, the heating device is started to continue to uniformly heat the base of the integral fixed table to 600-650 ℃, and the temperature rising speed is 80 ℃/h.

Compared with the prior art, the utility model discloses a cracked welding set of large-scale wheel fixed station base and repair technology, welding set can provide effectual guarantee for the fixed station base when welding, avoids welding process deflection too big, cooperates this repair technology, and not only safe easy operation, welding quality is stable, the investment cost is lower, has satisfied on-the-spot actual demand, and work efficiency is high, and greatly reduced the cost of maintenance, has reduced long-time process shutdown loss, provides the guarantee for rationally organizing to produce various wheels; additionally, a cracked welding set of large-scale wheel fixed station base and repair technology also provide scientific reference basis for the welding restoration of various large-scale steel casting spare parts from now on.

Drawings

Fig. 1 is a schematic view of a welding device for a broken base of a large wheel fixing table according to the present invention;

fig. 2 is a schematic view of a middle structural member frame according to the present invention;

FIG. 3 is a schematic view of a heating apparatus according to the present invention;

fig. 4 is an exploded view of the welding device for the base of the large wheel fixing station of the present invention;

FIG. 5 is a schematic view of the welding repair of the welding seam of the fixing table base of the present invention;

in the figure: 1. a fixed table base; 1A, a first bevel face; 1B, a second bevel face; 2. a level adjustment plate; 3. a structural member frame; 31. a base plate; 32. a support leg; 33. a frame unit; 34. a left and right adjusting screw; 35. a screw rod is adjusted forwards and backwards; 36. adjusting the screw rod up and down; 37. reinforcing a steel plate in a triangular mode; 4. a heating device; 41. a gas access pipe; 42. a gas main pipe; 43. a gas branch pipe; 44. and adjusting the valve.

Detailed Description

The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.

Unless defined otherwise, technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure belongs. The terms "upper", "lower", "left", "right", "front", "rear", and the like used in the specification and claims of the present disclosure are used only to indicate relative positional relationships, and when the absolute position of a described object is changed, the relative positional relationships are changed accordingly.

Example 1:

as shown in fig. 1 to 4, the utility model relates to a welding device for the fracture of a large wheel fixing station base, which comprises a structural component frame 3 and heating devices 4 respectively arranged at the front side and the rear side in the structural component frame 3, wherein the structural component frame 3 is used for placing a fixing station base 1 to be repaired, and the heating devices 4 are used for preheating and heating the fixing station base 1 before welding and heating up after welding when repairing; the bottom of the structural member frame 3 is provided with an upper and lower levelness adjusting device, the left and right sides of the structural member frame are provided with left and right pairing fixing devices, and the front and rear sides of the structural member frame are provided with front and rear pairing fixing devices; and a horizontal adjusting plate 2 is also arranged on the upper and lower levelness adjusting devices. In this embodiment, after the horizontal adjustment plate 2 in the structure frame 3 is put into to fixed station base 1, through the levelness adjusting device adjustment fixed station base 1's levelness from top to bottom, then fix fixed station base 1 all around through controlling group to the device and the group is fixed to fixing device around to, the welding of being convenient for is restoreed.

In this embodiment, structure frame 3 includes that bottom plate 31, equipartition set up two frame element 33 at bottom plate 31 top at a plurality of stabilizer blades 32 and symmetry interval in bottom plate 31 bottom, bottom plate 31, frame element with level adjusting plate 2 all adopts the preparation of 50mm steel sheet, stabilizer blade 32 is through the preparation of 80mm square steel. Further, the upper and lower levelness adjusting device comprises a plurality of upper and lower adjusting screws 36 uniformly penetrating the bottom plate 31, the upper and lower adjusting screws 36 are arranged on the bottom plate 31 by forming threaded holes thereon, and levelness adjustment of the level adjusting plate 2 and the fixed table base 1 placed thereon is performed by screwing; the left and right pairing and fixing device comprises a plurality of left and right adjusting screws 34 which are respectively arranged on the outer sides of the left and right frame units 33 in a penetrating way; the front-back pairing fixing device comprises a plurality of front-back adjusting screw rods 35 which are uniformly arranged on the front side and the back side of each frame unit 33 in a penetrating manner; the left and right adjusting screws 34 and the front and back adjusting screws 35 are respectively arranged on the frame unit 33 through threaded holes, and the fixing table base 1 which is assembled backwards and adjusted in levelness is fixed by screwing the left and right adjusting screws 34 and the front and back adjusting screws 35, so that welding repair is facilitated. In this embodiment, the two frame units 33 are spaced from each other, so as to facilitate the installation of the heating device 4 and the welding repair of the broken part of the fixing table base 1.

In this embodiment, the heating device 4 is a gas heating device, and includes a gas inlet pipe 41, a gas main pipe 42 is disposed on the gas inlet pipe 41, a plurality of gas branch pipes 43 are vertically communicated with the gas main pipe 42, and a plurality of nozzles are uniformly disposed on each gas branch pipe 43. Further, the gas inlet pipe 41 is further provided with an adjusting valve 44 for adjusting the amount of the gas so as to control the heating temperature. In the embodiment, each gas pipeline is made of steel pipes with the diameter of 40mm, so that the preheating of welding seams, interlayer temperature maintaining and postweld heat treatment are conveniently controlled during normal welding.

In order to increase the stability of the structural member frame 3, a plurality of triangular reinforcing steel plates 37 are uniformly welded between each supporting leg 32 and the bottom plate 31; a plurality of triangular reinforcing steel plates 37 are uniformly welded between the outer side of the frame unit 33 and the bottom plate 31. The triangular reinforcing steel plate 37 is made of a steel plate with the thickness of 30 mm.

Example 2:

as shown in fig. 1 to 5, a repair process of a welding device for a broken base of a large wheel fixing station according to embodiment 1 includes the following steps:

firstly, welding pretreatment of a fixed table base 1; firstly, respectively arranging a first bevel face 1A and a second bevel face 1B at a fracture part of a fixed table base 1, then inserting the fixed table base 1 into horizontal adjusting plates 2 in two frame units 33 of a structural member frame 3, pairing the first bevel face 1A and the second bevel face 1B at the fracture part of the fixed table base 1 to form an X-shaped groove, adjusting the horizontal adjusting plates 2 through upper and lower adjusting screws 36 to control the levelness of the fixed table base 1 after pairing, respectively controlling the left and right positions and the front and rear positions of the fixed table base 1 after pairing through left and right adjusting screws 34 and front and rear adjusting screws 35, locking and fixing according with the installation process size to prevent large welding deformation in the welding repair process, and finally connecting and fixing a heating device 4 on two sides of the X-shaped groove of the fixed table base 1;

step two, welding preparation;

2.1, welding equipment: HT400D digital control inversion type manual direct current argon arc welding machine, wherein welding materials are ER-50-6 welding wires with the diameter of 2.5mm, the purity of argon is more than or equal to 99.99%, Nb-500P digital pulse gas shielded welding is carried out, direct current positive connection is carried out, SWE71.1 flux-cored welding wires with the diameter of 1.2mm are selected as welding materials, and the purity of carbon dioxide is more than or equal to 99.8%;

2.2, oil stains, oxide layers, moisture and the like do not exist in the welding position area and the welding wire, and the metallic luster needs to be exposed;

2.3, welding technical requirements: the overlaying layer fuses base materials, and a welding seam cannot have any welding defects;

2.4, weldment material: z35 #;

2.5, auxiliary facilities: a heat-insulating barrel, a sample plate, a temperature measuring instrument, a magnifier, a mask, gloves, a slag removing hammer, a chisel, a file, a steel brush, abrasive paper, a steel ruler, a level bar, a movable spanner, a straight grinder, an angle grinder, a wire pliers, a steel saw blade, and labor protection articles (work clothes, shoes, caps and planoscopes);

2.6, setting welding process parameters according to welding equipment, weldment materials and welding materials;

manual tungsten electrode argon arc welding

Carbon dioxide arc welding

Step three, welding and repairing;

3.1, because the groove formed at the fracture part of the fixed table base 1 is a double-sided symmetrical X-shaped groove and is thicker, the two sides of the fixed table base 1 are simultaneously and uniformly preheated by the heating device 4 to reach the preheating temperature of 250-300 ℃, the heating temperature of the nozzle is uniformly transferred from the outside to the inside during preheating, the temperature rising speed is strived to be 50 ℃/h, so that the uneven high-temperature heating is avoided, the microcrack is generated inside the integral fixed table base 1, and the preheating is realized by heating the integral fixed table base 1, so that the local temperature difference stress can be reduced, the internal structure is improved, and the hardened structure is prevented or reduced;

3.2, simultaneously and symmetrically welding the backing layer on two sides of the X-shaped groove by adopting ER-50-6 welding wires through two argon arc welding machines, adding the welding wires to perform arc extinguishing welding continuously from bottom to top when the groove on one side is welded, enabling the vertical included angle between a welding gun and the groove to be 50-70 degrees, enabling the vertical inclination angle on the welding wires to be 20-40 degrees, not adding the welding wires into the welding machine on the other side, adopting self-melting backing welding, enabling the current to be larger than 15 percent of that of normal backing welding, melting through the root of backing on the back, and ensuring no welding defect, wherein the advantage of canceling the traditional welding to perform back-gouging and re-welding is that not only welding materials are saved, but also the original base metal is kept from being damaged, and the welding quality is effectively ensured;

3.3, after welding of the bottom layer is finished and no welding defect is detected, welding a filling layer from bottom to top symmetrically by two carbon dioxide gas shielded welding machines by using SWE71.1 flux-cored wires, welding the filling layer in multiple layers and multiple channels according to the width of a groove, detecting that the welding seam has no welding defect by visual inspection and a magnifying glass of 5 times, and then welding the next layer;

3.4, after the welding of the filling layer is finished and no welding defect is detected, the covering layer is welded from bottom to top by two carbon dioxide gas shielded welding machines through SWE71.1 flux-cored wires simultaneously and symmetrically, the covering layer is welded in multiple layers and multiple channels according to the width of a groove, the interlayer temperature is kept at 200-250 ℃, a welding gun vertically forms an angle of 80-90 degrees with the groove, a crescent operation method is adopted, each layer needs to be detected through visual inspection and a 5-time magnifier to detect that no welding defect exists in a welding seam, then the next layer is welded, particularly, the welding seam of the covering layer is higher than the base metal and smoothly transits with the two sides of the base metal, after all welding of the through cracks are finished, the covering layer is cooled to room temperature and then is subjected to all-directional detection instrument flaw detection welding detection and detection;

3.5, after confirming no any welding defect, both sides welder takes away simultaneously, restart heating device and continue to carry out even intensification to whole fixed station base 1 and heat to 600 ~ 650 ℃ and constant temperature 4 hours, then slowly fall to 250, during the heating, strive for even 80 °/h of temperature rise, in order to reduce the hardening degree, avoid embrittlement and eliminate welding stress, adopt the asbestos to wrap slowly and cool down to the room temperature again, adopt the mechanical grinding processing to accord with the use size to the whole fixed station base that the welding was accomplished at last, and after according with the technological requirement through detecting, put into service.

The above is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention should be covered by the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope defined by the claims.

Claims (6)

1. A welding device for the breakage of a base of a large wheel fixing table is characterized by comprising a structural member frame (3) and heating devices (4) respectively arranged at the front side and the rear side in the structural member frame (3); the bottom of the structural member frame (3) is provided with an upper and lower levelness adjusting device, the left and right sides of the structural member frame are provided with left and right assembly fixing devices, and the front and rear sides of the structural member frame are provided with front and rear assembly fixing devices; and a horizontal adjusting plate (2) is also arranged on the upper and lower levelness adjusting devices.

2. The welding device for the base fracture of the large wheel fixing table according to the claim 1, characterized in that the structural member frame (3) comprises a bottom plate (31), a plurality of support legs (32) uniformly distributed at the bottom of the bottom plate (31), and two frame units (33) symmetrically arranged at the top of the bottom plate (31) at intervals.

3. The welding device for the base fracture of the large wheel fixing table according to claim 2, wherein the upper and lower levelness adjusting device comprises a plurality of upper and lower adjusting screws (36) which are uniformly arranged on the bottom plate (31) in a penetrating manner; the left and right pairing and fixing device comprises a plurality of left and right adjusting screw rods (34) which are respectively arranged on the outer sides of the left and right frame units (33) in a penetrating manner; the front and rear pairing fixing device comprises a plurality of front and rear adjusting screw rods (35) which are uniformly arranged on the front side and the rear side of each frame unit (33) in a penetrating mode.

4. The welding device for the broken base of the large wheel fixing table according to any one of claims 1 to 3, wherein the heating device (4) is a gas heating device and comprises a gas access pipe (41), a gas main pipe (42) is arranged on the gas access pipe (41), a plurality of gas branch pipes (43) are vertically communicated with the gas main pipe (42), and a plurality of nozzles are uniformly arranged on each gas branch pipe (43).

5. The welding device for the base fracture of the large wheel fixing table according to claim 4, characterized in that the gas inlet pipe (41) is further provided with a regulating valve (44).

6. The welding device for the base fracture of the large wheel fixing table according to claim 2, characterized in that a plurality of triangular reinforcing steel plates (37) are uniformly welded between each supporting leg (32) and the bottom plate (31); a plurality of triangular reinforcing steel plates (37) are uniformly welded between the outer side of the frame unit (33) and the bottom plate (31).

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