Self-adjusting roller frame safety operation procedures
1. The self-adjusting roller frame should be installed in a firm, ventilated, rain-proof, moisture-proof and dust-proof place, away from violent vibration and knock. It is forbidden to spray corrosive liquid on the equipment.
2. It is forbidden to spray corrosive liquid on the equipment. When the driving and driven roller frames are installed at the same time, it is necessary to ensure that the driving and driven roller frames are horizontally equal in height and the center line is on the same straight line, and measure the diagonal lines of the driving and driven roller frames for adjustment.
3. Requirements for placing the workpiece: The diameter and weight of the workpiece should be strictly in accordance with the design regulations, otherwise safety accidents will easily occur, and the distance between the main wheel and the auxiliary wheel should be appropriately adjusted according to the length of the equipment.
4. The rubber wheel is only suitable for working at normal temperature. Under special circumstances, the highest temperature at the contact between the workpiece and the rubber tire is not allowed to be higher than 75 degrees, otherwise the rubber tire will be damaged. .
5. When in use, the roller should be in full contact with the workpiece, and it is forbidden to contact the weld or sharp parts. At the same time, when lifting the workpiece, it is forbidden to hit the roller to prevent the roller or other parts from being damaged. Under the condition that the equipment is not fixed, a strong impact is likely to lead to the subversion of the whole machine.
6. The debugging roller frame is gradually adjusted from low speed to high speed when it is started. When changing steering, you can only change it after the motor stops, otherwise it will easily cause the motor to burn out. During operation, it is forbidden to separate man and machine, and it is forbidden to stand within the rotating radius of the workpiece.
7, in order to ensure the performance of the equipment, before use, the transmission parts should be fully lubricated, and the equipment to fill in the daily inspection and maintenance records. After the whole machine is used for a period of time, it should be inspected regularly and the maintenance record form should be filled in.
8. The equipment adopts three-phase 380V AC power supply. For safe operation, the incoming line of the power supply must pass through the air switch. When debugging the equipment, turn on the power supply, press the start button and observe whether the driving wheel rotates normally. If there is any abnormality, immediately cut off the power supply and find out the reason. After troubleshooting, turn on the power and start the test.
9. Check and remove obstacles on the equipment before use, and use and keep it by special personnel. The roller frame assembly (rubber wheel) should not come into contact with oil and fire. 1. Automatically adjust the swing angle of the wheelset according to the diameter of the workpiece, and can automatically align it. When it is used with welding operator and welding power supply, it can realize the welding of internal and external longitudinal seam and internal and external circumferential seam of workpiece.
2. The transmission noise is low, the workpiece rotates smoothly, and the processes of welding, polishing, rubber lining and assembly of the cylinder can be realized, and the rotating speed of the cylinder should be stable and uniform. Crawling is not allowed.
3. Overvoltage protection, self-protection function, fault display and storage function, automatic air switch short-circuit protection, preset parameters.
4. Adjust the height of driving roller and driven roller properly, and assemble and weld cones and segmented unequal diameter rotors.
5. For some non-circular long weldments, they can be clamped by a special ring fixture or assembled and welded on the welding wheel frame.
6. Self-adjusting roller frame adopts digital adjustment and display technology of roller speed, and the setting of welding speed is very intuitive and accurate, which reduces the operation difficulty of workers.
7. The manufacturing and assembly accuracy of the roller frame should meet the requirements of grade 8 accuracy in national standards. The roller frame should be made of high quality steel. If the base of welded structure is used, stress relief heat treatment must be carried out after welding.
8. The roller frame must be equipped with reliable conductive devices, and welding current is not allowed to flow through the bearings of the roller frame.
9. When welding a cylindrical workpiece on the anti-axial movement roller frame, the axial movement of the workpiece should be ≤ 3mm during the whole welding process.
10. The center distance of each pair of rollers in the roller frame must be adjusted according to the diameter of the cylindrical workpiece, so as to ensure that the wrapping angle of the two roller pairs is 45 and less than 1 10.
1 1. equipped with 15m control cable, roller forward and backward switch, proximity switch and remote control switch.
12. The roller is preferably made of polyurethane or polybutadiene rubber. Adjustable roller frame is a kind of displacement machine that drives the weldment to rotate by the friction between the driving roller and the weldment. Only one roller part of the adjustable roller frame is the driving roller part and the other roller part is the driven roller part. The variable frequency motor is used as the driving device, and the roller parts are dragged by the reducer to drive the weldment to do welding rotation. The spacing adjustment of roller parts in each roller frame is manually completed by positioning bolts according to the welding situation.
Welding rotator is an advanced welding equipment developed by our factory by absorbing advanced equipment at home and abroad. It is mainly used for assembly, grinding and welding of pipes, vessels, boilers, pressure vessels, oil tanks, etc. It can be used together with columns, suspenders and saw systems to realize internal and external circumferential and longitudinal seam welding. Its series includes self-aligning rotator (SAR) and traditional rotator (WR). Other custom-made anti-drift rotators with car tilt; Therefore, the device has the advantages of compact structure, small volume, beautiful appearance, light weight and convenient operation. This machine can cooperate with all kinds of automatic welding or manual welding to improve welding quality, reduce welding labor and improve productivity.
We can provide unique welding rotating body solutions according to the customer's demand model.
(Domestic model HGZ##) Maximum bearing capacity
Maximum load capacity (ton) Application diameter range
Vascular diameter
φ d-φ d (mm) drum diameter. The wheel motor power with width, diameter and width is less than D3. When bearing the maximum load, only the two rollers rotate at a dim speed. Gross weight (length * width * height)
(ton) rubber wheel
D 1*W 1 (mm) metal wheel metal
D2 * w2 (mm) Maximum load d3 diameter d3 (mm) Active power
Passive idler
(mm) SAR 55 250-2300 250×100 2× 240× 20 0.75 3.75 757 0.1-1m/min
VFD 1620 * 690 * 700 1380 * 380 * 700 0.85 sar 10 10 320-2800 300× 120 2×290×25 1.5 7.5 9 10 / kloc-0/880 * 780 * 820 1450 7.2 SAR 200 200 1800-8000/550 * 260 7.5 150 2730 4800 * 900 * 1500 3480 * 550 * 1 500100 sar 250 250100 65438 the drum is divided into self-adjusting/adjustable drum stands, and the imported frequency converter realizes stepless speed regulation, with wide speed regulation range, large starting torque, high precision, low transmission noise and stable working rotation. The manual control box is simple and reliable to operate, and there is a linkage interface in the electric control cabinet, which can be connected with the operator control system produced by our company to realize linkage operation. This product is widely used for manual welding and automatic welding of non-ferrous metal (thin-walled and soft metal) cylinders.
Main technical parameters and specifications HG3-20HG3-30HG3-50HG3-100 Load (t) 20 30 50 100 Roller set diameter (mm) 350 400 400 500 wheel width (mm) 120 Total width (mm) 20 4500 5000 Minimum diameter (mm) 500 750100438+0065 2665×1470×135 3080×1500×14/kloc.
Based on the adjustable roller frame, the roller of the driven frame is made to be up and down, and the amount of workpiece channeling is detected by photoelectric encoder, and the system controller controls the lifting of the driven roller. The displacement detection frame is placed at one end of the workpiece, and the detection wheel is pressed on the end face of the workpiece (the end face must be machined). The detection wheel can rotate with the workpiece. When the workpiece moves axially, the detection wheel will follow the workpiece. The photoelectric encoder detects the quantity and direction of the workpiece, and its signal is input to the system controller for processing. The controller will adjust the lifting stroke, vertical speed and lifting interval of the driven roller according to the channeling amount, and control the lifting or lowering according to the channeling direction. The channeling momentum of the workpiece always fluctuates between-1.5mm and+1.5mm, which limits the channeling momentum of the workpiece to a certain range and can meet the needs of welding.
Welded roller frame
The welding wheel frame is a device that drives the cylindrical (or conical) weldment to rotate through the friction between the weldment and the driving wheel.
The welding roller frame is characterized by applying pressure without filling materials during welding. Most pressure welding methods, such as diffusion welding, high frequency welding and cold pressure welding, have no melting process, so there is no problem of beneficial alloy elements burning and harmful elements invading the weld like fusion welding. Welding the roller frame simplifies the welding process and improves the welding safety and hygiene conditions. At the same time, because the heating temperature is lower than that of fusion welding, the heating time is short and the heat affected zone is small. Many materials that are difficult to weld by fusion welding can often be welded by pressure welding into high-quality joints with the same strength as the parent metal.
The welding wheel frame is a kind of welding auxiliary equipment, especially a welding wheel frame, which is often used to weld the inner and outer circumferential seams and the inner and outer longitudinal seams of cylindrical workpieces. Comprises a base, a driving roller, a driven roller, a bracket, a transmission device, a power device drive and the like. The driving roller is driven by the transmission device, and the friction between the driving roller and the cylindrical workpiece drives the workpiece to rotate to realize displacement, so that the horizontal position welding of the inner and outer circumferential seams and the inner and outer longitudinal seams of the workpiece is realized, and the automatic welding is realized with the automatic welding equipment, which can greatly improve the welding quality, reduce the labor intensity and improve the working efficiency. The welding roller frame can also be used for manual welding or as a device for detecting and assembling cylindrical workpieces.
Working principle and application of welding roller frame
Working principle: the driving roller is driven by the transmission device, and the friction between the driving roller and the cylindrical workpiece drives the workpiece to rotate to realize displacement, which can realize the horizontal position welding of the inner and outer circumferential seams and the inner and outer longitudinal seams of the workpiece, and can realize automatic welding with automatic welding equipment.
Usage: mainly used for cylinder assembly and welding. If the height of the driving and driven rollers is properly adjusted, the assembly and welding of the vertebral body and the segmented unequal length warp rotator can also be carried out. For some non-circular long weldments, if they are clamped by special ring clamps, they can also be assembled and welded on the welding wheel frame. The welding roller frame can also cooperate with manual welding as a device for detecting and assembling cylindrical workpieces. The use of welding roller frame can greatly improve welding quality, reduce labor intensity and improve work efficiency.
Classification of welded roller frames
What kinds of welded roller frames are there? The following will introduce the classification of welded roller frames:
Self-adjusting welding wheel carrier Self-adjusting welding wheel carrier is a displacement device which uses the friction between the driving wheel and the workpiece to drive the workpiece to rotate. The swing angle of the wheel set can be automatically adjusted according to the diameter of the workpiece, and the center can be automatically adjusted. Mainly used for assembling or welding cylindrical workpieces such as pipes, containers, boilers and oil tanks. With the cooperation of welding operators and welding power supply, the welding of internal and external longitudinal seams and internal and external circumferential seams of workpieces can be realized.
Adjustable welding wheel frame The adjustable welding wheel frame consists of an active welding wheel frame and a passive welding wheel frame. The driving roller is driven by two motors respectively, and the governor realizes stepless speed change through variable frequency speed regulation or electromagnetic speed regulation of speed regulating motors. The rotating linear speed of the workpiece is 6-60 m/h, which can meet the needs of different welding such as manual welding, automatic surfacing welding and automatic submerged arc welding, as well as various riveting purposes of the workpiece. The distance between rollers can be adjusted by screws or screwdrivers to meet the welding requirements of workpieces with different specifications.
Anti-channeling welding roller frame The anti-channeling welding roller frame is based on the adjustable roller frame, and the roller of the driven frame is made to be liftable. The channeling of the workpiece is detected by the photoelectric encoder, and the system controller controls the lifting of the driven roller. The displacement detection frame is placed at one end of the workpiece, and the detection wheel is pressed on the end face of the workpiece (the end face must be machined). The detection wheel can rotate with the workpiece. When the workpiece moves axially, the detection wheel will follow the workpiece. The photoelectric encoder detects the quantity and direction of the workpiece, and its signal is input to the system controller for processing. The controller will adjust the lifting stroke, vertical speed and lifting interval of the driven roller according to the channeling amount, and control the lifting or lowering according to the channeling direction. The channeling momentum of the workpiece always fluctuates between-1.5mm and+1.5mm, which limits the channeling momentum of the workpiece to a certain range and can meet the needs of welding.
Electric drum frame operating procedure
1, the operator must be familiar with the basic structure and performance of the machine, reasonably choose the scope of application, master the operation and maintenance, and understand the knowledge of electrical safety.
2. When the roller is placed on the roller frame, it is necessary to check whether the center line of the idler is parallel to the center line of the roller, so as to ensure even contact and wear between the idler and the roller.
3. Adjust the focal length of the two groups of torus centers to be 60 5 degrees with the center of the cylinder. If the drum is offset, a protective device should be added to prevent the drum from stringing out when it rotates.
4. The roller frame must be adjusted when the machine is stopped.
5. When starting the motor, first close the two-pole switch in the control box and turn on the power supply, and then press the "forward rotation" or "reverse rotation" button according to the welding requirements. To stop the rotation, press the Stop button. If you need to change the direction of rotation in the middle, you must first press the "Stop" button to adjust the direction and turn on the power of the speed control box. The speed of the motor is controlled by the speed control knob in the control box.
6. When starting, adjust the speed control knob to the low speed position to reduce the starting current, and then adjust it to the required speed according to the operation requirements.
7. In all sectors of activity. Lubricating oil must be filled in each shift, and the lubricating oil in each turbine box and bearing should be checked regularly; ZG 1-5 calcium-based grease is recommended for bearing lubricating oil, and the method of frequent replacement is adopted.