Installation of mechanised plasma welding deposition for details of type "shaft" |
|
IPC classes for russian patent Installation of mechanised plasma welding deposition for details of type "shaft" (RU 2379164):
 Method to recover and strengthen ploughshares by eliminating radial wear via two-layer building-up / 2370351
Invention relates to repair of machinery and welding, namely to the method to recover and strengthen ploughshares by eliminating radial wear via two-layer build-up. Proposed method comprises building up worn-out working surface by electrode material. Here, building up of two different-hardness layers is performed along the radial wear axis. First layer is built up by electrode with carbon content in steel rod not exceeding 0.1% and rolls of plastic built-up metal are produced with their height set depending upon the depth of radial wear. Second layer is built up by wear-resistant electrode to the thickness smaller than that of the first layer.
 Method of car truck bolster saddle build-up electric arc welding / 2369472
Proposed method comprises mounting and fixing the bolster on rotary mechanism followed by build-up welding in rotating the bolster. Aforesaid operations are performed at the angle of bolster rotation mechanism elevation angle varying from 8 to 12 degrees. Build-up is made by open arc with welding electrode inclined to generating line of bearing surface at 50° to 60°, while build-up interval makes 1/3 to 1/6 of saddle depth.
Method of welding railroad rails / 2356712
Invention relates to methods of electric arc welding and can be used for railroad rails welding together. In compliance with the proposed method, first, metal peeling and spalling points are sought for on rolling surfaces of rail joints in hardened layer. When defined, aforesaid points are abraded, the rail is measured and marked using non-destructive test techniques. The rail head is heated to, at least, 400°C and worn rail joint surfaces are subjected to resurface welding to increase the size of repaired joint. Then, joint is cooled down and mechanically processed. The said resurface welding is performed over the entire width of rail head at reverse-polarity continuous current by applying deposited bead to overlap previously deposited bead along the repaired joint perimetre, starting crosswise from the rail nonworking part.
 Method for high speed argon-arc welding of cylindrical parts / 2356708
Invention may be used in manufacture and repair of machine cylindrical parts, for instance in worn out shafts, for instance for application of special alloys on shaft journals. Surface of rotary part is heated by electric arc to condition close to melting. Filler wire, end of which has shape of cone, is oriented with its longitudinal axis relative to axis of part rotation at the angle and is supplied to zone of arc burning with permanent axial force. Filler is rotated under condition of match between vector of cone base circular speed and vector of part generatrix circular speed. Filler wire is supplied with the speed that is 1.15…1.25 times more than the rate of its melting. Tungsten electrode relative to axis of wire rotation is diverged in plane that is perpendicular to axis of rotation for 24…28° to the side that is opposite to part rotation, and also for 16…18° in direction of welding. Arc capacity is increased simultaneously with connection of line feed.
Electric-arc deposit welding method / 2355530
Present invention can be used in depositing corrosion-resistant, heat-resistant coating from Ni-Al alloys on objects made from carbon and alloy steel. During deposit welding using a non-consumable electrode in inert shielding gases, a nickel wire is put into the welding arc in front of the welding burner, and an aluminium wire is put into the welding bath behind the welding burner.
 Process of receiving of metal coating by overlaying welding method with ultra-fine grained structure and reinforced particles in nanoscale range / 2350441
Method includes production of adding material from the mixture of powders and binding agent in the form of two pastes. The first paste consists of binding agent and nanopowder of heat-resistant material with particles diameters 10-70 nm and with the melting temperature more than for 400°C higher of liquid metal temperature of in molten metal. The second paste consists of bending agent and powders mixture of materials, providing service properties of fused coating. After it on the product surface it is applied paste layer of the first content by thickness 0.1-0.4 mm and mass 0.5-4.0% of facing material mass, and then on the first layer it is applied paste layer of the second content of thickness 2.0-5.0 mm. Then paste layers are dried till total moisture removal and it is implemented full meltdown of both paste layers and meltdown of product surface with fusion penetration grade 0.03-0.4.
Composition of powder material for restoration of construction machinery and road machines details / 2342467
Invention concerns composition of powder material for plasma fusing of coatings and can be used in mechanical engineering for restoration of details' worn surface of construction machinery and road machines. Composition includes mixture of powder based on iron and powder based on nickel. At that powder based on iron contains, wt %: carbon 3.3-3.5, silicon 2.0-2.5, manganese 10-12, boron 2.5-3.0, titanium 3,0-4,0, iron -the rest. Powder based on nickel contains, wt %: carbon 0.9-1.5, chrome 16-18, silicon 4.5-5.0, boron 4.0-4.7, nickel - the rest. Content of powder based on iron and powder based on nickel in mixture is respectively 70-75% and 30-25%.
Method of cast iron forming roll wobblers repair / 2335387
Forming roll wobbler is preliminarily heated with the rate of 50-70°C/hr to the temperature of 180-200°C. Removal of defective areas, pad welding and further thermal treatment is carried out at specified temperature. At that pad welding is performed at current density of 12-28 A/mm2.
 Method of wear resistance increase of ploughshare / 2334384
Electrode material is distributed over the most wearing part of the working surface by U-shape rollers or rollers having the shape of semiellipse. Beading is carried out continuously followed by fast cooling of the edge in water in order to form hardening structure.
 Method of electroarc facing by modulated current / 2333083
Invention is related to method of electroarc facing of corrosion-preventive coating with modulated current and may be used in production of equipment from austenite chromium-nickel steels, which is intended for processing of radiated nuclear fuel, and also for equipment of chemical industry. Facing of coating is carried out with application of additional activating current pulse onto arc gap. Application of additional activating current pulse is performed directly prior to working pulse after passage of pause current with amplitude of 250-300 A and duration of 0.001-0.0015 sec. Besides, facing is carried out with melting electrode with diameter of up to 4 mm.
 Section for production of box-like welded products / 2378097
Invention may be used to make welded products of box-like shape, for instance transformer vessels with corrugated walls. Device for installation, assembly and welding of products includes at least two units of fixation of parts with manipulators. At least one welding burner joined to welding transformer is installed on portal with the possibility of parallel and perpendicular motion. Device for loading of parts and unloading of finished products is arranged in the form of cargo trolley with the possibility of its displacement along rails arranged parallel to portal. On trolley there is a lifting-turning receiving table mounted with mechanism of parts retention in the form of cam clamps and lifting-turning boom. Lifting-turning receiving table is arranged with the possibility to dismantle welded product from manipulator and is equipped with hinged platform for its location. Rail tracks are arranged with outlet beyond portal zone.
 Installation for welding of closed seams with alternation of rectilinear and curvilinear sections / 2377109
Invention can be used in machine-building production chain with computer-aided production process for welding of closed seams with drive feed of welded products. Welding machine for seam welding is outfitted by two sensors of welded edges, contains immovable desk with ball bushings and copy roller. Plate with four restrictive planks for fixation on it of bottom part is implemented with guiding grooves parallel to straight-line portion of welding seam. At intersection of grooves in points of connection of radiuses of curvilinear sections of seams there are implemented cavities. Copy roller is installed with ability of movement in tracking grooves of plate by axis of welding in plane parallel to roller electrodes and it is outfitted by spring-loaded axis. Axis is connected to rod of electromagnetic valve with ability of its fixation in mentioned grooves. Immovable desk is outfitted by ball bushings and two planks for limitation against movement of welded welded edges of product. Plate is installed in contact to ball bushing of immovable desk and copy roller.
 Method of assembling box-type items for welding / 2376120
Method can be used during manufacture of box-type welded items, namely housings of transformers with corrugated walls. Frame of cover and bottom are installed in manipulator and fixed with spring-loaded spacer levers. Levers contact opposite located beams having hinged connections to face plate. Frame of cover is held down to limit stops mounted on spacer levers. Before the first corrugated wall is laid, electromagnets are installed on frame of cover and bottom. Corrugated wall is held down to electromagnets and its tack welding is performed. Then electromagnets are removed and face-plate is turned with manipulator through 90°. The second corrugated wall is laid, held down by flanging to edge of the first corrugated wall and tack welding is performed. The same is done to the third and fourth corrugated walls.
 Device for automatic welding of sector branches of pipelines / 2376119
Invention refers to device for automatic welding of sector branches of pipelines and can be used during manufacture of welded rectangular expansion joints of pipes thermal expansion. Column and housing are mounted on the device base. Lower rollers are installed on housing symmetrically relative to column axis. Their drive is located inside housing. On column there fixed with possibility of being rotated is lead screw end passing through lead screw nut located on cantilever hold-down beam and the other end of lead screw is installed on upper end of column. On beam there mounted are upper rollers and welding unit with duplicating roller. Position switch is located on housing. Detachable cam with magnet lock is designed to be fixed on sector branch with possibility of interacting the position switch. Welding unit is installed with possibility of independent vertical movement by means of independent drive along guides. Guides are rigidly fixed on connecting rod of welding machine passed through holes made in bracket fixed on cantilever hold-down beam whereon two spring-loaded hold-down rollers are located symmetrically to vertical column axis. Two pairs of driving rollers kinematically connected to drive are located on housing. Contact surfaces of hold-down and driving rollers are copper plated.
 Device for continuous production of flat nets / 2376115
Invention refers to device used for production of flat nets and is designed for welding of nets of 0.2-5 mm wire, and up to 2.5 m wide in construction industry, as well as for production of quality products from the net in furniture trade. Weft wire supplying mechanism of the device consists of carriage for receiving and cutting weft wire and magnetic pick-and-place mechanism for moving weft wire to welding position. Carriage is installed on the base of welding machine and includes two side walls wherebetween a beam is rigidly fixed, and receiving shaft is installed on walls so that it can be rotated. Rolling supports are installed on carriage side walls to provide movement of carriage along guides of welding machine base. On one of the above side carriage walls there installed is initial position sensor of receiving shaft, which is equipped with longitudinal guide slots made of hardened inserts for receiving weft wire. On the beam there rigidly fixed are restricting plates with semi-rings. Edges of plates are located opposite one of longitudinal slots of receiving shaft and comprise weft wire receiving channel, and semi-rings are installed coaxially to receiving shaft and intended for retaining weft wire in slots when receiving shaft is turned. On beam there installed with possibility of longitudinal movement is sensor indicating that weft wire is in the channel, and shears with drive for cutting weft wire are fixed. Magnetic pick-and-place mechanism is installed on welding machine base and includes two racks on each of which brackets are fixed, and in brackets on axes there installed are housings in which pins are rigidly fixed on both sides. Pins are installed on one side of housing in vertical position and on them there fixed with possibility of being adjusted as to height is beam with levers-catchers, which is located parallel to receiving shaft. Levers-catchers are located opposite longitudinal unloading slot of receiving shaft and on them there installed are constant magnets which are protected with hardened patches, and free ends of pins on the other side of the above housings are rigidly connected to forks which are hinged to levers, the other ends of which are fixed so that they can be rolled on beam with upper electrode blocks.
 Welder training simulator of manual arc welding with consumable and non-consumable electrode / 2373040
Simulator includes a welding tool with welding electrode, manipulator with welding pattern (10), having current leads and current-carrying branches, welding current source (8), two current sensors (1, 12), voltage sensor (2), two-axis angular position sensor (13) of welding electrode, control unit (14) of filler material supply, normalising amplifiers (3,4,15,16,17,18), multiple-channel analogue-digital converter (5), personal computer (6) and device (7) for reproducing sound signals of feedback with the welder being taught, which is connected to audio output of computer (6). Outputs of current sensors (1,12), voltage sensor (2), two-axis sensor (13) of angular positions of welding electrode and control unit (14) of filler material supply are connected to appropriate inputs of corresponding normalising amplifiers, the outputs of which are connected to inputs of analogue-digital converter (5), the output of which is connected to data bus of personal computer (6). One pole of current source (8) is connected to current lead of welding electrode, and the other pole - to connection point of two current-carrying branches of manipulator (9), and each current-carrying branch is connected with another point to one of two current leads of manipulator (9), in which there installed and fixed is welding pattern (10) with edges opposite as to its length. Each current sensor (1, 12) is connected to one of appropriate current-carrying branches of manipulator (9).
 Machine for pressure contact butt-seam welding of rails by flashing / 2372177
Invention relates to the equipment for pressure contact butt-seam welding by flashing, in particular for the fixed machines for welding of rails into long lengths. Machine for pressure contact butt-seam welding of rails by flashing consists of mobile and immobile pillars connected with each other by shafts, upset cylinders, welding equipment, outboard roller centralisers and flash-taker joint. The joint consists of mobile flash-taker plates with actuator's hydrocylinders, immobile arm support brackets with bearing plates. Outboard rollers of the centraliser are made to enable centering along the base of rail. Hydrocylinders of the flash-taker plates' actuator is made to leave the pass for isolated joint during its opening (i.e. sufficient pass is available). Bearing plates have the form to enable the pass of the isolated joint. Arm support bracket of the flash-taker is equipped with removable guidepaths for advance centering of the rail along the base.
 Method for filter production / 2361069
Invention is related to method for filter production and may find application in oil production industry, method includes application of metal filtering mesh around external periphery of support shell and fastening of metal filtering mesh to external periphery of support shell by means of welding, at that metal filtering mesh fully covers all filtering openings of support shell, creating filter shell. Then filter shell is fixed to external periphery of basic pipe so that filter shell fully covers all penetrating holes of basic pipe. Jacket is applied around external periphery of filter shell and fixed to external periphery of basic pipe so that jacket fully covers external surface of filter shell filtration. Spot and seam welding technologies are used for fixation of metal mesh directly to external periphery of support shell, eliminating possibility of leaks, bypassing filter, in areas of metal mesh welding. As a result, filter is produced from multi-layer metal mesh with improved properties of sand collection and prolonged service life.
 Welding mill assembly / 2359799
Invention relates to welding, particularly to welding mill assemblies and can be used in making longitudinal welded pipes of large diametre. The welding mill assembly has an a viaduct with guides on which are mounted an actuated carriage of the welding set, clamping mechanism, which includes support and clamping jaws, mechanism of bringing together edges of the moulded pipe shell and apparatus for installing a separating blade. The mechanism for lifting the pipe shell is in form of a frame, bearing prism and lifting carrier rollers. The mechanism for bringing together longitudinal edges is made in form of synchronously moved single-arm pivoted levers, mounted on the frame symmetrically about the axis of the pipe shell. The free ends of the levers have spring-loaded supports, which interact with the pipe shell. Separating blades are rigidly mounted at the ends of the single-arm pivoted levers, mounted at the ends of the viaduct on the side opposite the guides with the carriage.
 Welding mill / 2358848
Welding mill consists of immobile portal with welding equipment, two roll tables, two devices to transfer grooved panels and turner. The said immobile portal mounted at the roll table centre is furnished with suspensions whereon welding equipment is mounted, representing welding heads with vertical and horizontal slides, and their number corresponding to double number of the panel lengthwise seams to be welded together. The turner mounted at the roll table rear end comprises separate independent drive sections mounted to roller supports and representing disks with openings arranged aligned with roll tables, furnished with vertical extending supports and horizontal adjustable rests interacting with the shelves, and grooved panel walls, respectively. Each of the said two roll tables consists of two types of isolated sections furnished with horizontal and vertical rollers adjustable in horizontal plane. Note that vertical rollers on one of two types of sections are spring-loaded, while the sections of one of the roll tables are furnished with additional horizontal rollers.
 Method and device for contact butt welding of rolled strips in continuous metallurgical units / 2378092
Invention is related to welding production, namely to method and device for contact butt welding of strips, which is executed on specialised butt welding machines installed in continuous metallurgical units. Strips are moved while grips of fixed and movable bed plates of welding machine are lifted. Fixed bed plate is drawn aside by value of initial distance between grips of bed plate clamps, and strip ends are fed till stop. They are pressed in grips of movable and fixed bed plates clamps and welded. On completion of welding clamps are lifted. Movable bed plate is drawn aside by half of initial distance between grips of machine bed plate clamps, and welded strip is transported into unit. After passage of welding axis strip end, which is arranged as front according to direction of feed into unit, clamp of fixed bed plate is put down. Reverse is used to return strip end, which is arranged as front according to direction of feed into unit, until stop at grips of fixed bed plate clamp, and specified strip end is pressed in grips of movable bed plate clamp. Upper clamp of fixed machine is lifted, and the following strip is fed into machine till stop of its end, which is arranged as back towards direction of feed into unit, against upper grip of movable bed plate clamp. Movable bed plate is drawn aside by value of initial distance between grips of machine bed plate clamps, and back end of strip is pressed in grips of fixed bed plate clamp for execution of the next welding session.
|
FIELD: metallurgy. SUBSTANCE: installation contains stand and installed in it carriage consisting of front and back mandrel for fixation of treated detail. Workhead drive installed on carriage consists of electric motor, drive belting, bearing mount assembly and tachometre generator. Workhead drive installed on carriage consists of electric motor, drive belting, bearing mount assembly and tachometre generator. Detail is installed in centers and as additional bearing for long-measuring details it is used centering device. On stand it is fixed blacket with located on it plasmatron, mechanism of wire feeding, device for thickness control of pad, pyrometre for heating control of detail surface before plasma arc front. On stand there are installed limit switches restricting movement of carriage. Movement drive, rotation drive, plasmatron with feeding mechanism of wire, device for control and pyrometre are connected to control assembly. EFFECT: ability of regulation of detail rotating frequency, rate of movement of detail and providing of control of pad thickness. 1 dwg
The invention relates to the field of engineering, namely welding, in particular to installations for mechanized plasma deposition, and may find application in the repair of shafts and other parts. Designed for plasma welding of shafts when restoring or padding. For mechanized plasma welding shafts are commonly used installation that contains the mechanisms of rotation of the product, move the torch and feeding the filler material, and a control device associated with the mechanisms for feeding the filler material and the movement of the plasma torch. Analogous to the claimed device can serve as an installation for plasma-powder cladding of shafts (Sidorov A.I. Restoration of machine parts by spraying and welding. - M.: Mashinostroenie, 1987, p.63, Fig.16). The disadvantage of this setup is that the welding is carried out without control for the desired frequency of rotation of the workpiece, the speed of moving parts, and without control of the thickness of the deposited layer and without sufficient consideration of thermal processes. Known installation of mechanized plasma welding shafts patent No. 2114724. The disadvantage of this setup is that when the coating on the surface of the part is not taken into account the frequency of rotation of the workpiece and the speed of moving parts, which degrades the quality of the welding, and is also not taken into account control of the thickness of the deposited layer, that, in turn, can complicate subsequent machining. During welding, the depth of penetration can be changed several times, which leads to various defects (discontinuities in composition, structure and physical-mechanical properties). Technical challenge is the ability to control the speed of detail and speed of moving parts and control the thickness of the deposited layer. The technical result is to obtain a uniform coating on parts like "Shaft" on the composition, structure and physical-mechanical properties and, consequently, increase quality, improve machining and subsequent operational characteristics of the weld surface. This technical result is achieved by setting for mechanized plasma welding parts of type "Shaft". The installation is characterized by the fact that it comprises a frame and set it on the carriage, consisting of front and tailstock for fastening the workpiece. The rotation drive part mounted on the carriage consists of a motor, belt, bearing unit and tachometer. The carriage drive consists of a motor, gearbox, belt drive and tachometer. The item is installed in the centers, but as more is positive support for long parts of the centering device. On the frame is fixed bracket placed on it by the plasmatron, a wire feeder, a device for controlling the thickness of the deposited layer, the pyrometer to control heating of the workpiece surface in front of the plasma arc. On the frame is installed limit switches limiting the movement of the carriage. The travel drive, the drive spins, the plasmatron with a wire feeder, the control device and the pyrometer is connected to the control unit. The technical problem is solved due to the fact that the installation is provided with a rotation drive part, consisting of motor, belt drive, the bearing unit and the tachometer, the carriage drive consisting of a motor, gearbox, belt drive and tachometer, and a device for controlling the thickness of the deposited layer, and all the devices connected to the control unit. The scheme of installation of mechanized welding is shown in the drawing. The installation comprises a frame 1 on which the carriage consisting of a front 2 and rear 3 headstock, which is attached to the item type Shaft 4, the rotational drive 5 parts, consisting of an electric motor 6, a belt 7, the bearing unit 8 and the Tacho-generator 9, a longitudinal displacement drive of the carriage 10, consisting of an electric motor 11, the gear 12, belt p is passing 13 and tachometer 14, which moves the carriage with the lead screw 15, the carriage is limited by the movement with the help of limit switches 16, for details of the big sizes as additional base is used in the centering device 17, on the frame bracket fixed plasmatron 18 with the wire feeder 19, pyrometer 20 and the control device 21, all devices connected to the control unit 22, The device operates as follows. Item 4 is fixed in the centers, the plasmatron 18 is installed in the original position with a certain gap between the surface and the nozzle of the plasmatron, after which the control unit 22 starts the rotation drive 5 parts like Shaft 4 and the arc is ignited. The plasmatron 18 heats the surface of the part 4 to the temperature limit of thermal saturation in the selected mode. The pyrometer 20 controls the heating of the surface in front of the plasma arc, when the set temperature is reached, the control unit 22 receives information from the pyrometer 20 and in turn launches the longitudinal displacement drive of the 10 items, and gives a signal to the plasmatron 18 of applying surfacing material. During the welding device 21 controls the thickness of the fused layer. In case of deviation from specified dimensions of the layer, the control unit 22 reads the information from the control device 21 and provides a signal to drive rodallega move the carriage 10 and the rotational drive 5 parts changing accordingly the speed of moving parts and the rotational speed of the workpiece through tachogenerators 9, 14. Stable conditions of deposition and uniformity of the coating composition, structure and physical-mechanical properties can be achieved through the necessary speed and speed of moving parts, and also by controlling the thickness of the deposited layer. The frequency of rotation and the speed of moving parts to control the respective actuators. To achieve the set temperature of melting of the parent metal, the control unit receives information from the pyrometer and starts the carriage drive. During deposition control device controls the thickness of the fused layer. Installation of mechanized plasma welding parts like Shaft, characterized in that it comprises a frame and set it on the carriage, consisting of front and tailstock for fastening the workpiece and the rotation drive part, consisting of motor, belt drive, the bearing unit and the tachometer, the carriage drive consisting of a motor, gearbox, belt drive and tachometer, centering device, as additional support for the workpiece, the bracket is placed on it by the plasmatron with a wire feeder, give the your to control the thickness of the deposited layer, the pyrometer to control heating of the workpiece surface in front of the plasma arc and limit switches limiting the movement of the carriage, and the carriage drive, the rotation drive part, the plasmatron with a wire feeder, a device for controlling the thickness of the deposited layer and the pyrometer is connected to the control unit.
|