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首页:公司动态 >> 托辊焊接工艺的否定与反思

托辊焊接是指托辊辊皮与冲压轴承座之间采用CO2气体保护焊焊接,从托辊的技术要求衡量,采用焊接工艺是不恰当的。 图1是DTⅡ型托辊辊体的设计图,两端轴承座A-B同心度Φ0.03 ,采用 CO2气体保护焊焊接,显然是保证不了同心度的。 钢材在焊接时熔化,钢的熔化温度1500℃左右,在这个温度下,轴承座和辊皮产生较大的热变形。产生较大变形的原因主要有三点,其一是轴承座、辊皮厚度范围3-5mm,属于轻薄件,温度扩散较慢产生变形,其二是焊接工艺是逐渐焊接的过程,轴承座和辊皮在焊接过程中温升不均匀产生变形,其三是冲压轴承座一般不消除应力,受热后应力释放产生变形。总之,多种变形叠加,造成托辊阻力增加,降低了托辊寿命,增大了功率消耗。 图1 DTⅡ辊体 从加工角度说,辊皮是精度比较高的加工件,如图2,冲压轴承座有些企业为了提高质量,也要进行二次机加工,在零件质量达到IT9精度的情况下,再用焊接工艺焊接显然也是不匹配的选择。 影响轴承座A-B同心度的原因还有许多,比如轴承座的精度和强度、轴承座与辊皮的配合、辊皮两端镗孔的精度及同心度等等。这些因素,本文暂不探讨。 托辊轴承座与辊皮的结构有许多种方式,主要的结构方式经过了两次演化。早期是TD62型、TD75型带式输送机,托辊轴承座与辊皮采用紧配合压装形式,轴承座采用铸铁材料,也有轴承座采用折边冲压,见图3。后期是DTⅡ型带式输送机,托辊轴承座与辊皮采用CO2气体保护焊焊接,轴承座采用冲压轴承座,如图1 。 图2 辊皮 演化的原因,除了铸铁轴承座本身的缺点和加工效率低下外,主要是当时的加工手段落后,保证不了辊子两端轴承座的同心度和管子与轴承座的可靠连接。 图3 TD75型 棍子 目前托辊加工设备经过30年的缓慢发展,一种全新加工工艺的数控自动化托辊生产线、托辊加工设备已经进入市场,前述两种轴承座与辊皮连接的缺点得到了根本的改变。 这种全新加工工艺的设备,采用了“一种托辊轴承座与辊皮的连接设备及方法”的发明专利(专利号:CN201110048425.6),解决了前述两种轴承座与辊皮连接的缺点。同时,为了解决目前托辊镗孔设备辊皮镗孔同心度较低,造成托辊阻力大的问题,辊皮定心不准确,造成托辊径向圆跳动量大的问题,又采用了“托辊辊皮加工自动定位夹持装置”发明专利技术(专利号:ZL201320885767.8)。 由于全新加工工艺设备采用了新工艺,实现了托辊全数字化加工,托辊加工质量得到了显著提高,托辊的阻力、径向圆跳动量、轴向窜动量都小于GB/T10595-2006标准规定值25%以上,为高速大运量带式输送机托辊的制造提供了保障。 Roller welding is refers to the idler roller between skin and pressing bearing using CO2 gas shielded welding machine, welding from the technical requirements of roller, the welding process is inappropriate. Figure 1 is A DT Ⅱ type roller roller body design, both ends of bearing A - B concentricity Φ 0.03, using CO2 gas shielded welding machine, welding is clearly not ensure concentricity. Steel melt during welding, steel melting temperature about 1500 ℃, under this temperature, bearing and roller skin produce larger thermal deformation. Causes of large deformation mainly has three, one is the range, thickness of roller bearing 3-5 mm, belong to the thin pieces, deformation temperature diffusion is slow, the other is welding technology is gradually welding process, and roller bearing temperature uneven deformation in the welding process, a third is pressing bearing seat is generally not eliminate stress, heat stress released after deformation. In a word, a variety of deformation superposition, causing resistance increases, the roller reduced the roller life and increase the power consumption. Figure 1 DT Ⅱ roller body in terms of processing, roll skin is relatively high precision mechanical parts, as shown in figure 2, the press bearing some enterprise in order to improve the quality, also must carry on the secondary machining, in the case of parts quality reaches IT9 precision, then use the choice of welding technology welding is obviously not matching. Impact bearing A - B concentricity and there are many causes, such as the precision and intensity of the bearing, bearing and roller skin, and the precision of roll skin on both ends of the boring and concentricity and so on. These factors, temporarily not discussed in this paper. Roller bearing and the structure of the roller skin there are many ways, the structure of the main ways after twice evolution. Early is TD62, TD75 type belt conveyor, roller bearing and roller adopt tight fit being connected in form, with cast iron bearing material, also have a bearing use ruffled stamping, as shown in figure 3. Late is DT Ⅱ type belt conveyor, roller bearing and roller skin using CO2 gas shielded welding machine, welding by pressing bearing, bearing as shown in figure 1. Figure 2 roll skin evolutionary reasons, in addition to the shortcomings of cast iron housings and machining efficiency is low, mainly processing means lag behind at that time, ensure that both ends of the roller bearing concentricity and pipe and the reliable connection of the bearing. Figure 3 TD75 stick The roller processing equipment after 30 years of slow development, a new processing technology of numerical control automatic production line for roller, roller processing equipment has entered the market, the two kinds of bearing seat connected with roller skin defects got change fundamentally. This kind of new processing technology equipment, adopted "a kind of roller bearing and roller skin connection device and method" of invention patent (patent number: CN201110048425.6), solved the two bearing seat connected to the roller skin defects. At the same time, in order to solve the current roller skin boring boring equipment roller bearing is low, causing the problem of large roller resistance, inaccurate centering roll skin, causing a large quantity of roller radial circular runout problem, and adopted the "roller roller skin processing automatic positioning clamping device" invention patent technology (patent number: ZL201320885767.8). Because of the equipment used the new technology, new processing technology realized the full digital processing roller, roller processing quality got improved significantly, the resistance of the roller, radial circular runout and axial channeling momentum is less than e. more than 25%, GB/T10595-2006 standard for manufacturing high speed large capacity belt conveyor idlers.

[来源:原创] [作者:aowl] [日期:18-11-07] [热度:]
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