【作者】 杨超；

【导师】 刘红旗；

【作者基本信息】 机械科学研究总院 ， 机械设计及理论， 2008， 硕士

【摘要】 针对国内高压大口径厚壁管件(弯头、三通、管帽和异径接头)市场庞大,制造技术滞后,缺乏成熟工艺和成套设备的现状,研究开发了一套包括操作机、变位焊接机、坡口切边机等的高压大口径厚壁管件制造的专用设备,并通过数值模拟和实验相结合,提出了一套以热压制和焊接为基础的管件制造工艺。论文重点对管件热压制过程中工件的搬运、位姿变换以及弯头的焊接工艺过程进行了研究,同时对锻压操作机、切边坡口机和自动化埋弧变位焊接机等成套专用设备进行了设计和计算分析。根据管件种类与规格繁多的特性,在设计锻压操作机时考虑了多种工况的多种动作需求,设计了5-6个自由度的操作动作和可拆换的操作机械手套件,实现了“一机多用”的目标。根据管件压制工艺流程的要求,综合分析了操作机要完成的功能以及要实现的动作、动作的方法、次序和时间,充分缩短了工件从在加热炉到压机之间的操作时间,确保了热压制对温度的要求。变位焊接机的设计采用了“扇一笼”式结构,同时,创造性采用了上、下弦变位焊接机配合使用的模式,不仅简化了单台设备的结构、尺寸重量、成本和制造难度,解决了弯头内焊缝焊接的难题,而且实现了焊接的流水作业,提高了工作效率。根据弯头的结构特点和下弦变位焊接机的焊缝特点,研究了新的变位原理,提出了基于平行四边形原理的绕近似重心回转的连杆联动式同步变位焊接机和绕近似重心回转的伺服驱动式变位焊接机。申请了国家专利一项。切边坡口机的设计考虑了管线钢的热敏感性,增加了火焰切割热去除影响区工序,在加工坡口时采用铣削的方式避免再次形成热影响区。相对于目前较为普遍的半手工制造或功能相对单一的自制简陋设备,成套专用设备自动化程度高,操作时的劳动强度低,管件的质量有了质的提高。因此,专用设备的研制为高压大口径厚壁管件的制造提供了有力的技术支撑,同时也间接的支持了西气东输二线和中亚管线等大型工程的建设。更多还原

【Abstract】 There is a big market for high pressure, huge caliber and thick wall pipe fitting (elbow, tee, cap and reducer), while the lag in manufacturing technology and the lack of mature techniques and complete equipment set couldn’t be ignored as well. Therefore, a set of equipments that focus on the fittings with high performance has been designed and produced in response to the situation mentioned before. Furthermore, by the use of numeral simulation and experimentation, a set of the high-performance pipe fitting manufacturing techniques on the basis of heat press and welds has been introduced as well.There are three problems mainly discussed in this paper: the move of work piece during the heat-pressing process of pipe fitting, the position- change during the heat-pressing process of pipe fitting, and the process of elbow welding techniques. Meanwhile, forging operators, pipe-end facing machines and automatic location-changing welding machine have been well designed and calculated.Since pipe fitting possesses great varieties and standards, all kinds of demands for the various working conditions have been taken into consideration when the forging operator is designed. There two designs that make the machine a multiple-use machine: one is the operating movement with 5～6 selections, the other is the "operating manipulator" fitting which is available for teardown and displacement. According to the requirement of pipe fitting pressing process, the functions and motions are analyzed roundly; the study of every motion’s mode, order and time has greatly saved the operating time for the work piece moving from heater to forging presser, which insures the temperature for heat-pressing.The location-changing welding machine has a fan-cage-mixed structure. Meanwhile, the first quarter location-changing welding machine and the last quarter location-changing welding machine works together, not only simplifying the structure, weight, cost and manufacture difficulty, giving a solution to the welding of elbow inside cracks, but also actualizing continuous welding and making the work more efficient. According to the characteristic of the elbow welding and the last quarter location-changing welding machine, the author studied a new theory of location-changing; as a consequence, a location-changing welding machine which works in phase has been designed on the basis of parallelogram principle.Considering the heat sensitivity of pipeline steel, a working procedure wiping off the heat affected zone has been introduced. By milling groove, a new heat affected zone can be prevented from forming.Comparing with half-handcraft-manufactured equipment or home-made single-functional sets that are prevalent at present, the whole set of equipments which are highly automatized can reduce the labor intensity and improve the pipe fitting’s quality. Therefore, the whole set of equipments not only provide a mighty support for the production of the high pressure, huge caliber and thick wall pipe fitting, but also support many large projects such as Mid-Asian pipeline project.更多还原