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    首頁:公司動態 >> 托輥焊接工藝的否定與反思
    托輥焊接是指托輥輥皮與沖壓軸承座之間采用CO2氣體保護焊焊接,從托輥的技術要求衡量,采用焊接工藝是不恰當的。 圖1是DTⅡ型托輥輥體的設計圖,兩端軸承座A-B同心度Φ0.03 ,采用 CO2氣體保護焊焊接,顯然是保證不了同心度的。 鋼材在焊接時熔化,鋼的熔化溫度1500℃左右,在這個溫度下,軸承座和輥皮產生較大的熱變形。產生較大變形的原因主要有三點,其一是軸承座、輥皮厚度范圍3-5mm,屬于輕薄件,溫度擴散較慢產生變形,其二是焊接工藝是逐漸焊接的過程,軸承座和輥皮在焊接過程中溫升不均勻產生變形,其三是沖壓軸承座一般不消除應力,受熱后應力釋放產生變形。總之,多種變形疊加,造成托輥阻力增加,降低了托輥壽命,增大了功率消耗。 圖1 DTⅡ輥體 從加工角度說,輥皮是精度比較高的加工件,如圖2,沖壓軸承座有些企業為了提高質量,也要進行二次機加工,在零件質量達到IT9精度的情況下,再用焊接工藝焊接顯然也是不匹配的選擇。 影響軸承座A-B同心度的原因還有許多,比如軸承座的精度和強度、軸承座與輥皮的配合、輥皮兩端鏜孔的精度及同心度等等。這些因素,本文暫不探討。 托輥軸承座與輥皮的結構有許多種方式,主要的結構方式經過了兩次演化。早期是TD62型、TD75型帶式輸送機,托輥軸承座與輥皮采用緊配合壓裝形式,軸承座采用鑄鐵材料,也有軸承座采用折邊沖壓,見圖3。后期是DTⅡ型帶式輸送機,托輥軸承座與輥皮采用CO2氣體保護焊焊接,軸承座采用沖壓軸承座,如圖1 。 圖2 輥皮 演化的原因,除了鑄鐵軸承座本身的缺點和加工效率低下外,主要是當時的加工手段落后,保證不了輥子兩端軸承座的同心度和管子與軸承座的可靠連接。 圖3 TD75型 棍子 目前托輥加工設備經過30年的緩慢發展,一種全新加工工藝的數控自動化托輥生產線、托輥加工設備已經進入市場,前述兩種軸承座與輥皮連接的缺點得到了根本的改變。 這種全新加工工藝的設備,采用了“一種托輥軸承座與輥皮的連接設備及方法”的發明專利(專利號:CN201110048425.6),解決了前述兩種軸承座與輥皮連接的缺點。同時,為了解決目前托輥鏜孔設備輥皮鏜孔同心度較低,造成托輥阻力大的問題,輥皮定心不準確,造成托輥徑向圓跳動量大的問題,又采用了“托輥輥皮加工自動定位夾持裝置”發明專利技術(專利號:ZL201320885767.8)。 由于全新加工工藝設備采用了新工藝,實現了托輥全數字化加工,托輥加工質量得到了顯著提高,托輥的阻力、徑向圓跳動量、軸向竄動量都小于GB/T10595-2006標準規定值25%以上,為高速大運量帶式輸送機托輥的制造提供了保障。 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.
    [來源:原創] [作者:aywl] [日期:17-02-21] [熱度:]
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