CN115430898A - Aluminum sheath helium-free welding device, production line and method - Google Patents
Aluminum sheath helium-free welding device, production line and method Download PDFInfo
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- CN115430898A CN115430898A CN202211212928.7A CN202211212928A CN115430898A CN 115430898 A CN115430898 A CN 115430898A CN 202211212928 A CN202211212928 A CN 202211212928A CN 115430898 A CN115430898 A CN 115430898A
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- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims abstract description 15
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K13/00—Welding by high-frequency current heating
- B23K13/01—Welding by high-frequency current heating by induction heating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
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Abstract
The invention relates to an aluminum sheath helium-free welding device, a production line and a method thereof, wherein the aluminum sheath helium-free welding device comprises: the forming mechanism comprises an extrusion module for extruding and forming the cable core and the pure aluminum strip into an aluminum strip and a coating module for coating the aluminum strip into a tubular aluminum strip; the welding induction mechanism is arranged on the discharging side of the forming mechanism; the welding induction mechanism comprises a connecting rod and an induction coil which are welded together; the cable core and the pure aluminum strip are formed into a tubular aluminum strip through a forming mechanism, the tubular aluminum strip penetrates through an induction coil of a welding induction mechanism, and the tubular aluminum strip is continuously welded through the induction coil through electromagnetic induction under the condition that the welding induction mechanism is electrified. The invention does not need helium protection, utilizes three large effects (skin effect, proximity effect and circular ring effect) of induction to concentrate heating energy on the end surface of the metal to be welded, heats the metal to be molten by depending on eddy current generated in the metal, and rapidly extrudes oxide and metal impurities on the welding surface to realize reliable welding.
Description
Technical Field
The invention relates to the technical field of manufacturing of metal shielding layers of railway signal cables, in particular to a helium-free welding device and method for an aluminum sheath.
Background
The railway signal cable is applied to a high-speed railway signal system to transmit railway signals, and is a necessary core technical product for high-speed railway construction.
With reference to fig. 1 and 2, the railway signal cable comprises an outer sheath, namely an outer protective layer, and a cable core in the outer protective layer, wherein a steel strip armor layer, an inner liner layer, a hot melt adhesive coating layer, a heat insulation layer and a belting layer are arranged between the outer protective layer and the cable core; the core wires in the cable core can be divided into a plurality of four-wire groups, paired wire groups and core wires, wherein the core wires are provided with insulating layers, the paired wire groups at least comprise one four-wire group consisting of four core wires, and the four-wire group is provided with an aluminum sheath, namely a metal shielding layer.
In the manufacturing process of the metal shielding layer of the railway signal cable, the aluminum sheath and the cable core are required to be welded and combined. The existing welding processes include the following:
1. argon arc welding: the welding material is melted into liquid on the welded base material by high current to form a molten pool, so that the welding material is metallurgically bonded. The existing disadvantages are that: (1) the speed is low when the welding quality is stable; (2) helium protection is required; (3) Ultraviolet rays are generated during welding, and certain harm is caused to human bodies.
2. Laser welding: the method is to weld by using the heat generated by bombarding the weldment with focused laser beam as energy source. The existing disadvantages are that: (1) The cost of the laser and the related system is high, and the investment is large; (2) High assembly precision of weldment, low photoelectric conversion efficiency and the like.
3. Utilizing a simulation machine: and extruding a plurality of aluminum rods into an aluminum sheath to cover the surface of the cable core in a special extrusion mode. The existing disadvantages are that: (1) only the pipe diameter below phi 14mm can be extruded; (2) the production speed is 3m/min at most, and the production efficiency is low; and (3) acid and alkali washing is needed, so that the environment is not protected.
In summary, the following steps: the existing welding process needs helium or helium protection, has high requirements on the quality of an aluminum strip, and has low production line speed and low yield.
Disclosure of Invention
Aiming at the defects of the prior art, the invention discloses a helium-free welding device for an aluminum sheath, a production line and a method thereof.
The technical scheme adopted by the invention is as follows:
an aluminum sheath no helium welding apparatus comprising:
the forming mechanism comprises an extrusion module for extruding and forming the cable core and the pure aluminum strip into an aluminum strip and a coating module for coating the aluminum strip into a tubular aluminum strip; the extrusion module comprises at least one group of upper forming wheel and lower forming wheel, and the cable core and the pure aluminum belt enter between the upper forming wheel and the lower forming wheel together to be extruded and formed into an aluminum belt; the cladding module comprises at least one group of horizontal wheels, and the aluminum strip enters the group of horizontal wheels to be wrapped into an aluminum tube;
the welding induction mechanism is arranged on the discharging side of the forming mechanism; the welding induction mechanism comprises a connecting rod and an induction coil which are welded together;
the cable core and the pure aluminum strip are formed into the tubular aluminum strip through the forming mechanism, the tubular aluminum strip penetrates through an induction coil of the welding induction mechanism, and the tubular aluminum strip is continuously welded through the induction coil under the condition that the welding induction mechanism is electrified.
The method is further technically characterized in that: the molding mechanism further includes a support module that supports the extrusion module and the cladding module.
The method is further technically characterized in that: the supporting module comprises a front support, a mounting plate and a rear support, and the front support and the rear support are respectively arranged on two sides of the mounting plate; the extrusion module and the coating module are arranged on the mounting plate.
The method is further technically characterized in that: the forming mechanism further comprises a guide belt wheel, and the guide belt wheel is arranged on one side of the feeding portion of the forming mechanism.
The method is further technically characterized in that: the forming mechanism further comprises a wire pressing wheel, and the wire pressing wheel is arranged between the extrusion module and the coating module.
The method is further technically characterized in that: the forming mechanism further comprises a height adjusting module, and the height adjusting module adjusts the height of the coating module to enable the height of the coating module to be matched with the height of the welding induction mechanism; the height adjusting module comprises a lifting nut, a lifting base and a lifting screw rod, the lifting screw rod is fixed in the lifting base, the lifting screw rod supports the coating module, the lifting nut is adjusted to be located at the position of the lifting screw rod, and therefore the height of the coating module is adjusted.
The method is further technically characterized in that: the forming mechanism is characterized by further comprising a first belt passing device, a first belt integrating device, a side cutting device, a second belt passing device and a second belt integrating device which are arranged before feeding of the forming mechanism, wherein the first belt passing device conveys the pure aluminum belt, the first belt integrating device shapes the pure aluminum belt, the side cutting device cuts the side of the pure aluminum belt, the second belt passing device conveys the cable core, and the second belt integrating device shapes the cable core.
An aluminum sheath helium-free welding production line comprises a cable core pay-off rack, a first wire passing rack, a pure aluminum strip pay-off rack, an aluminum strip tension control device, a second wire passing rack, an aluminum strip edge cutting waste wire take-up reel and the aluminum sheath helium-free welding device; the cable core pay-off rack unreels the cable core, the first wire passing rack conveys the cable core, the pure aluminum tape pay-off rack unreels the pure aluminum tape, and the aluminum tape tension control device and the second wire passing rack convey the pure aluminum tape; and the aluminum sheath is pressed by a helium welding-free device, wraps the cable core and the pure aluminum tape and is welded to form the aluminum sheath.
The aluminum sheath helium-free welding method utilizing the aluminum sheath helium-free welding device comprises the following steps of:
s1, respectively conveying a cable core and a pure aluminum tape into the aluminum sheath helium-free welding device;
s2, carrying out shaping and trimming pretreatment on the cable core and the pure aluminum tape;
s3, the cable core in the step S2 is sleeved in the pure aluminum tape in the step S2 in a penetrating mode, and the cable core and the pure aluminum tape are extruded and wrapped to obtain a tubular aluminum tape;
and S4, the tubular aluminum strip penetrates through an induction coil of the welding induction mechanism, the welding linear velocity and the welding voltage coefficient of the welded aluminum pipe are controlled, and the tubular aluminum strip is welded in an induction mode to obtain the aluminum sheath.
The method is further technically characterized in that: in step S4, the welding linear velocity and the welding voltage coefficient are synchronously adjusted, the welding linear velocity is 5.5m/min-50.5m/min, and the welding voltage coefficient is 55.5% -95.5%.
Compared with the prior art, the technical scheme of the invention has the following advantages:
1. the helium-free welding device for the aluminum sheath disclosed by the invention concentrates heating energy on the end face of the metal to be welded by utilizing three induction effects (skin effect, proximity effect and circular ring effect), heats the metal to be molten by depending on eddy current generated in the metal, and rapidly extrudes oxide and metal impurities on the welding surface to realize reliable welding.
2. The aluminum sheath helium-free welding device adopts a non-contact induction welding technology, after the end surface of an aluminum strip to be welded is instantly heated to a molten state (550-580 ℃), a certain external force is applied, and the aluminum strip and the end surface are welded together through plastic deformation at a high temperature, so that breakthrough of efficiency and quality is realized.
3. The cable core in the aluminum sheath is composed of the copper core insulated wire core, and the copper conductor also has induction heating phenomenon in the electromagnetic induction environment to influence the insulation performance.
4. Because the high-frequency induction has the phenomena of proximity effect and skin effect, and the metal parts in the welding area also have the phenomenon of induction heating, the helium-free welding device for the aluminum sheath adopts special non-metal materials to manufacture a forming tool mold, thereby eliminating the influence of the metal parts in the induction area.
5. The aluminum sheath helium-free welding production line has lower requirement on the quality of the aluminum strip, and compared with the prior argon arc welding process, the flaring qualification rate is improved by 100 percent.
6. The aluminum sheath helium-free welding production line does not need helium protection, and the production cost for manufacturing the aluminum sheath is saved.
7. The linear speed for the production of the aluminum sheath helium-free welding production line is improved from 10m/min to 45m/min, and the production efficiency is improved by 350 percent.
Drawings
In order that the present invention may be more readily and clearly understood, reference will now be made in detail to the present invention, examples of which are illustrated in the accompanying drawings.
Fig. 1 is a cross-sectional view of a conventional railway signal cable.
Fig. 2 is a schematic structural diagram of a conventional railway signal cable.
FIG. 3 is a schematic view of an aluminum sheath no helium welding apparatus of the present invention.
Fig. 4 is a schematic view of the molding mechanism of fig. 3.
Fig. 5 isbase:Sub>A cross-sectional view taken atbase:Sub>A-base:Sub>A in fig. 4.
Fig. 6 is a cross-sectional view at B-B in fig. 4.
Fig. 7 is a cross-sectional view at C-C in fig. 6.
Fig. 8 is an assembled view of the support bracket and the support plate of fig. 4.
Fig. 9 is a schematic structural diagram of the welding induction mechanism in fig. 3.
Fig. 10 is a front view of the weld sensing mechanism of fig. 3.
Fig. 11 is a side view of the weld sensing mechanism of fig. 3.
FIG. 12 is a schematic view of an aluminum sheath helium-free welding line of the present invention.
The specification reference numbers indicate: 1. a cable core pay-off rack; 2. a first wire passing frame; 3. a pure aluminum belt pay-off rack; 4. an aluminum strip tension control device; 5. a second wire passing frame; 6. an aluminum strip trimming waste wire take-up reel; 7. a first passing device; 8. a first belt aligning device; 9. a trimming device; 10. a second passing device; 11. a second belt aligning device; 12. a molding mechanism; 1201. a first upper forming wheel; 1202. a first lower forming wheel; 1203. a second upper forming wheel; 1204. a second lower forming wheel; 1205. a first horizontal wheel; 1206. a second horizontal wheel; 1207. a wire pressing wheel; 1208. a line-pressing shaft; 1209. a guide pulley; 1210. a pulley shaft; 1211. a front bracket; 1212. a support shaft; 1213. a rear bracket; 1214. a lifting nut; 1215. a lifting base; 1216. a lifting screw; 1217. locking the nut; 1218. flattening the cushion; 1219. supporting the side plates; 1220. a first upper contoured axle; 1221. a positioning ring; 1222. a threaded sleeve; 1223. a hexagon socket head cap screw; 1224. a first lower contoured axle; 1225. a thin nut; 1226. a support plate for a shaft; 1227. a second upper contoured axle; 1228. a horizontal axle; 13. welding an induction mechanism; 14. an extrusion wheel; 15. a cable core; 16. pure aluminum strip.
Detailed Description
The present invention is further described below in conjunction with the following figures and specific examples so that those skilled in the art may better understand the present invention and practice it, but the examples are not intended to limit the present invention.
The foregoing and other technical matters, features and effects of the present invention will be apparent from the following detailed description of the embodiments, which is to be read in connection with the accompanying drawings. Directional terms as referred to in the following examples, for example: up, down, left, right, front or rear, etc., are simply directions with reference to the drawings. Therefore, the directional terminology used is for the purpose of describing, but not limiting, the invention, and moreover, like reference numerals designate like elements throughout the embodiments.
Example 1:
referring to fig. 3 and 4, an aluminum sheath no-he welding device includes:
the forming mechanism 12 comprises an extrusion module for extruding and forming the cable core 15 and the pure aluminum strip 16 into an aluminum strip and a coating module for coating the aluminum strip into a tubular aluminum strip; the extrusion module comprises at least one group of upper forming wheel and lower forming wheel, and the cable core 15 and the pure aluminum belt 16 enter between the upper forming wheel and the lower forming wheel together to be extruded and formed into an aluminum belt; the coating module comprises at least one group of horizontal wheels, and an aluminum belt enters the group of horizontal wheels to be coated into an aluminum pipe;
the welding induction mechanism 13 is arranged on the discharging side of the forming mechanism 12; the welding induction mechanism 13 comprises a connecting rod 1301 and an induction coil 1302 which are welded together;
the cable core 15 and the pure aluminum strip 16 are formed into a tubular aluminum strip through the forming mechanism 12, the tubular aluminum strip passes through the induction coil 1302 of the welding induction mechanism 13, and the tubular aluminum strip is continuously welded by the induction coil 1302 through electromagnetic induction under the condition that the welding induction mechanism 13 is electrified.
The aluminum sheath helium-free welding device solves the problems that the existing welding process needs helium or uses helium for protection, the requirement on the quality of an aluminum strip is high, the production line speed is low, and the yield is low.
In the embodiment, the proximity effect and the skin effect phenomenon exist in high-frequency induction, the induction heating phenomenon also exists in metal parts in the welding area, the upper forming wheel, the lower forming wheel and the horizontal wheel are made of non-metal materials, and the influence of the metal parts in the induction area is eliminated due to the non-metal materials such as high-molecular polyethylene, polycaprolactam (MC nylon) and the like.
In the present embodiment, the number of sets of the upper forming wheel and the lower forming wheel is two, and for convenience of description, the sets are respectively defined as a first upper forming wheel 1201, a first lower forming wheel 1202, a second upper forming wheel 1203 and a second lower forming wheel 1204, the first upper forming wheel 1201 and the first lower forming wheel 1202 are one set disposed above and below, and the second upper forming wheel 1203 and the second lower forming wheel 1204 are one set disposed above and below. Positioning rings 1221 are respectively arranged on two sides of the first upper forming wheel 1201, the first lower forming wheel 1202, the second upper forming wheel 1203 and the second lower forming wheel 1204 and used for limiting displacement of the forming wheels. The first upper forming wheel 1201 is mounted on the first upper forming wheel shaft 1220, a supporting side plate 1219 is arranged at one end of the first upper forming wheel shaft 1220, the supporting side plate 1219 is fixed on the first upper forming wheel shaft 1220 through a locking nut 1217, a flat gasket 1218 is arranged between the supporting side plate 1219 and the locking nut 1217, and the flat gasket 1218 is used for increasing the contact area between the locking nut 1217 and the supporting side plate 1219 and improving the locking force. The first lower forming wheel 1202 is mounted on a first lower forming wheel axle 1224, and a threaded sleeve 1222 and a hexagon socket head screw 1223 are provided at the end of the first lower forming wheel axle 1224 for securing the support side plate 1219. At least one thin nut 1225 is provided at the other end of the first lower form wheel axle 1224, and the thin nut 1225 is used to fix the first lower form wheel 1202. Second upper forming wheel 1203 is installed in second upper forming wheel shaft 1227, and the one end of second upper forming wheel shaft 1227 sets up axle and uses backup pad 1226, and axle is fixed in second upper forming wheel shaft 1227 through lock nut 1217 with backup pad 1226, sets up flat pad 1218 between axle and the lock nut 1217 with backup pad 1226, and in the same way, flat pad 1218 is used for increasing the area of contact of axle with backup pad 1226 and lock nut 1217, improves the locking force. A second lower forming wheel 1204 is mounted to the second lower forming wheel shaft.
In this embodiment, the number of the horizontal wheels is two, and for convenience of description, the horizontal wheels are respectively defined as a first horizontal wheel 1205 and a second horizontal wheel 1206, and the first horizontal wheel 1205 and the second horizontal wheel 1206 are respectively installed on the horizontal wheel shaft 1228. A thin nut 1225 is provided at one end of the horizontal axle 1228, and a lock nut 1217 and a flat washer 1218 are provided at the other end of the horizontal axle 1228.
In this embodiment, the molding mechanism 12 further includes a support module that supports the extrusion module and the sheathing module. Specifically, the support module includes a front bracket 1211, a mounting plate, and a rear bracket 1213, the front bracket 1211 and the rear bracket 1213 being disposed at both sides of the mounting plate, respectively; the extrusion module and the coating module are arranged on the mounting plate.
In this embodiment, the forming mechanism 12 further includes a guide pulley 1209, and the guide pulley 1209 is disposed on the feeding side of the forming mechanism 12.
In this embodiment, the molding mechanism 12 further includes a capstan 1207, and the capstan 1207 is disposed between the extrusion module and the sheathing module.
In this embodiment, the forming mechanism 12 further includes a height adjusting module, which adjusts the height of the cladding module to make the height of the cladding module adapt to the height of the welding sensing mechanism 13; the height adjusting module comprises a lifting nut 1214, a lifting base 1215 and a lifting screw 1216, the lifting screw 1216 is fixed in the lifting base 1215, the lifting screw 1216 supports the coating module, and the position of the lifting nut 1214 on the lifting screw 1216 is adjusted, so that the height of the coating module is adjusted.
In this embodiment, the helium-free welding device for the aluminum sheath further comprises a first passing device 7, a first belt shaping device 8, an edge cutting device 9, a second passing device 10 and a second belt shaping device 11 which are arranged before the feeding of the forming mechanism 12, wherein the first passing device 7 conveys a pure aluminum belt 16, the first belt shaping device 8 shapes the pure aluminum belt 16, the edge cutting device 9 cuts the edge of the pure aluminum belt 16, the second passing device 10 conveys a cable core 15, and the second belt shaping device 11 shapes the cable core 15.
The working principle of the embodiment is as follows:
the first tape passing device 7 conveys a pure aluminum tape 16 and shapes the pure aluminum tape 16 through the first tape arranging device 8, the edge cutting device 9 cuts the edge of the pure aluminum tape 16, and the second tape passing device 10 conveys the cable core 15 and shapes the cable core through the second tape arranging device 11;
the cable core 15 and the pure aluminum tape 16 enter a first upper forming wheel 1201, a first lower forming wheel 1202, a second upper forming wheel 1203 and a second lower forming wheel 1204 of the forming mechanism 12 together, and are extruded to obtain an aluminum tape, and then the aluminum tape is wrapped by a first horizontal wheel 1205 and a second horizontal wheel 1206 to obtain a tubular aluminum tape.
The tubular aluminum strip passes through the induction coil 1302 of the welding induction mechanism 13, and the welding linear velocity and the welding voltage coefficient of the welded aluminum tube are controlled, so that the tubular aluminum strip is induction-welded to obtain the aluminum sheath. The tubular aluminum strip adopts a non-contact induction welding technology, after the end surface of the aluminum strip to be welded is instantly heated to a molten state (550 ℃ -580 ℃), certain external force is applied, and the end surface is welded together through plastic deformation at a high temperature, so that breakthrough of efficiency and quality is realized. The convergence angle is an included angle formed when two sides of the aluminum strip enter extrusion points, a preheating section and a melting section (also called a lintel) can be formed at the edge of the aluminum strip, when the lintel section is heated violently, aluminum water in the lintel section is quickly vaporized and is exploded and splashed out to form flash, the size of the convergence angle directly influences the welding quality, and the convergence angle can be adjusted by adjusting the height of the coating module through adjusting the height adjusting module.
The no helium welding device of aluminium sheath that this embodiment provided satisfies accurate shaping and operation under electromagnetic induction environment, high temperature, the high load operating mode environment.
Example 2:
as shown in fig. 12, a helium-free welding production line for aluminum sheaths is characterized in that: the device comprises a cable core pay-off rack 1, a first wire passing rack 2, a pure aluminum tape pay-off rack 3, an aluminum tape tension control device 4, a second wire passing rack 5, an aluminum tape trimming waste wire take-up reel 6 and an aluminum sheath helium-free welding device as provided in example 1; the cable core pay-off rack 1 unreels the cable core 15, the first wire passing rack 2 conveys the cable core 15, the pure aluminum tape pay-off rack 3 unreels the pure aluminum tape 16, and the aluminum tape tension control device 4 and the second wire passing rack 5 convey the pure aluminum tape 16; the aluminum sheath is pressed by a helium welding-free device, wraps the cable core 15 and the pure aluminum tape 16 and is welded to form the aluminum sheath.
In this embodiment, the cable core pay-off rack 1, the first wire passing rack 2, the pure aluminum tape pay-off rack 3, the aluminum tape tension control device 4, the second wire passing rack 5 and the aluminum tape trimming waste wire take-up reel 6 are all the prior art, and the structure and the working principle thereof are common knowledge in the field, and are selected and adjusted by a person skilled in the art as required.
The working principle of the embodiment is as follows:
firstly, a cable core 15 is installed on a cable core pay-off rack 1, the tip of a first pay-off rack 2 is configured according to the size of an inner hole of a cable core disc of the cable core pay-off rack 1, the tip of the first pay-off rack 2 is locked, the tip of the first pay-off rack 2 is clamped, and proper tension is given; the cable core 15 is an upper outgoing line, a wire coil of the first pay-off rack 2 is installed at the center of the first pay-off rack 2, and test running confirmation is performed after installation is finished.
Before the pure aluminum strip 16 is installed, the two side surfaces of the pure aluminum strip 16 are checked to have no mechanical damage or oil stain and the like, if the large damage and deformation cannot be completely cut off in the strip cutting process during welding, the pure aluminum strip cannot be installed and produced; when the pollution is serious and the cleaning cannot be carried out, the installation and the production cannot be carried out. And (3) placing the pure aluminum strip 16 qualified by self-inspection on a pure aluminum strip pay-off rack 3, sequentially passing through each second wire passing rack 5, the fine cutter and the aluminum strip trimming waste wire take-up reel 6, and adjusting positioning devices such as an aluminum strip limiting block and the like at the fine cutter to ensure that the center of the pure aluminum strip 16 is consistent with the center of the fine cutter, and the aluminum strip trimming waste wire take-up reel 6 winds the pure aluminum strip waste material cut by the fine cutter.
Secondly, the first tape passing device 7 conveys the pure aluminum tape 16 and shapes the pure aluminum tape 16 through the first tape finishing device 8, the edge cutting device 9 cuts the edge of the pure aluminum tape 16, and the second tape passing device 10 conveys the cable core 15 and shapes the cable core through the second tape finishing device 11;
then, the cable core 15 and the pure aluminum tape 16 enter the first upper forming wheel 1201, the first lower forming wheel 1202, the second upper forming wheel 1203 and the second lower forming wheel 1204 of the forming mechanism 12 together, and are extruded to obtain an aluminum tape, and then the aluminum tape is wrapped by the first horizontal wheel 1205 and the second horizontal wheel 1206 to obtain a tubular aluminum tape.
Finally, the tubular aluminum strip is passed through the induction coil 1302 of the welding induction mechanism 13, and the welding linear velocity and the welding voltage coefficient of the welded aluminum tube are controlled, and the tubular aluminum strip is induction-welded to obtain the aluminum sheath.
Example 3:
an aluminum sheath helium-free welding method using the aluminum sheath helium-free welding device provided in embodiment 1 includes the following steps:
s1, respectively conveying the cable core 15 and the pure aluminum tape 16 into an aluminum sheath helium-free welding device;
s2, carrying out shaping and trimming pretreatment on the cable core 15 and the pure aluminum strip 16;
s3, the cable core 15 in the step S2 is sleeved in the pure aluminum tape 16 in the step S2 in a penetrating mode, and the cable core 15 and the pure aluminum tape 16 are extruded and wrapped to obtain a tubular aluminum tape;
and S4, the tubular aluminum strip penetrates through an induction coil 1302 of the welding induction mechanism 13, the welding linear velocity and the welding voltage coefficient of the welded aluminum pipe are controlled, and the tubular aluminum strip is welded in an induction mode to obtain the aluminum sheath.
In this embodiment, in step S4, the welding linear velocity and the welding voltage coefficient are synchronously adjusted, the welding linear velocity is 5.5m/min to 50.5m/min, and the welding voltage coefficient is 55.5% to 95.5%.
The specific process is as follows:
installing a die: mounting the forming mechanism 12: selecting the types of guide wheels of the forming mechanism 12 according to the specification of the aluminum sheath process card, namely the sizes of a first upper forming wheel 1201, a first lower forming wheel 1202, a second upper forming wheel 1203, a second lower forming wheel 1204, a first horizontal wheel 1205 and a second horizontal wheel 1206; the horizontal, vertical and relative positions are detected and adjusted by a predetermined operation tool and a predetermined measurement tool. The operation is required to be standardized, and the damage or deformation of the tool caused by the illegal operation cannot be caused.
Threading: sequentially passing the cable core 15 through a guide pulley 1209, a first upper forming wheel 1201, a first lower forming wheel 1203, a second upper forming wheel 1203 and a second lower forming wheel 1204 to a creasing wheel 1207; the pure aluminum strip 16 is passed through the second wire-passing frame 5, the edge-cutting device 9, and the end of the pure aluminum strip 16 is cut with a sharp angle of about 30 ° with scissors. The sharp corner then passes through a guide pulley 1209, a first upper forming wheel 1201, a first lower forming wheel 1203, a second upper forming wheel 1203 and a second lower forming wheel 1204 to a creasing wheel 1207. The pure aluminum tape 16 is connected by a traction rope fixed on the traction, and people are needed to convey the cable core 15 into the forming mechanism 12 at the welding station before the cable core 15 enters the forming mechanism 12.
Drawing an empty tube: after the forming mechanism 12, the material or the cable core 15 is replaced, the pure aluminum tape 16 is drawn into a hollow tube through the forming mechanism 12, the forming mechanism 12 is adjusted, the welding quality is checked, and the cable core 15 can be installed for production after confirmation.
Starting up and adjusting: the following welding factors were adjusted, such as:
width adjustment of the pure aluminum strip 16: and rotating a screw rod of the fine cutting knife, and adjusting the width of the fine cut pure aluminum strip 16 to meet the process requirement.
Traction adjustment: and (5) pressing a traction machine (used for drawing the finished product out) to the traction pull rod.
Adjusting the center of a welding seam: and adjusting the relative positions of all parts of the forming tool to enable the welding line to be positioned at the 12-point position of the clock.
Adjusting the welding quality: parameters are set, welding quality is visually observed, and whether a welding seam is flat and tight, whether deflection exists or not, periodic holes and other welding defects are observed.
Starting: after the welding quality is confirmed and verified by drawing the hollow tube, the cable core 15 is threaded to the guide pulley 1209, and the welding linear velocity and the welding voltage coefficient are synchronously adjusted. And the welding linear velocity and the welding voltage coefficient are gradually improved on the premise of stable welding.
Winding the flat cable: marking an aluminum sheath at the end part of the cable core 15 passing through the drawing die, shearing the mark after traction, and resetting the meter counter to start metering; fixed in the head hole at the bottom end of the take-up reel, the creel stand is started, and the gap and the speed of the flat cable are adjusted according to the outer diameter of the flat cable.
The reference table for the comparison between the welding linear velocity and the welding voltage coefficient of the aluminum sheath is shown in table 1.
TABLE 1 reference table for comparing welding linear speed and welding voltage coefficient of aluminum sheath
As can be seen from the above table, according to the specifications of different forming mechanisms 12, the welding linear velocity is 39.5m/min-44.5m/min, and the welding voltage coefficient is 55.5% -95.5%.
In addition, the process verification was performed on the aluminum sheath produced by the helium-free welding method for the aluminum sheath provided in example 3, and the verification records are shown in tables 2 to 7.
Table 2 process verification record 1 for aluminum sheath production line
The product model specification is as follows: LEU BSYL23 × 4 × 1.53, pure aluminum tape specification: 60mm is multiplied by 1.25mm, and the forming tool is as follows: Φ 20, drawing outside diameter: 16.5mm
TABLE 3 Process verification record of aluminum sheath production line (2)
The product model specification is as follows: SPTYWPL 23B × 1.0, pure aluminum strip specification: 70mm 1.25mm, shaping frock: phi 23, drawing outer diameter: 21.5mm
TABLE 4 Process verification record of aluminum sheath production line (3)
The product model specification is as follows: SPTYWPL 23B × 1.0, pure aluminum strip specification: 80mm 1.25mm, shaping frock: φ 26, draw OD: 24.5mm
TABLE 5 Process verification record of aluminum sheath production line (4)
The product model specification is as follows: SPTYWPL23 a × 1.0, pure aluminum tape specification: 90mm 1.25mm, shaping frock: φ 29, draw OD: 16.5mm
TABLE 6 Process verification record of aluminum sheath production line (5)
The product model specification is as follows: SPTYWPL 23B × 1.0, pure aluminum strip specification: 100mm × 1.25mm, molding tooling: φ 32, draw OD: 29.5mm
TABLE 7 Process verification record of aluminum sheath production line (6)
The product model specification is as follows: SPTYWPL 23B × 1.0, pure aluminum strip specification: 110mm × 1.25mm, molding tooling: phi 36, drawing outer diameter: 35mm
As can be known from the upper table, the cable core comprises copper core insulation core in the aluminium sheath, and the phenomenon that the copper conductor also has induction heating in the electromagnetic induction environment influences insulating properties, and through welding frequency control induction area, the protection to the cable core is realized, and it is crucial to satisfy quick butt fusion and the frequency that the copper conductor can not be heated. By adjusting the welding linear speed and the welding voltage coefficient, the aluminum sheath product meets the requirements of flaring and bending tests through debugging and verification.
In the description of the embodiments of the present invention, it should be further noted that unless otherwise explicitly stated or limited, the terms "disposed" and "connected" should be interpreted broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications of the invention may be made without departing from the scope of the invention.
Claims (10)
1. An aluminum sheath does not have helium welding device which characterized in that: the method comprises the following steps:
the forming mechanism (12) comprises an extrusion module for extruding and forming the cable core (15) and the pure aluminum strip (16) into an aluminum strip and a coating module for coating the aluminum strip into a tubular aluminum strip; the extrusion module comprises at least one group of upper forming wheel and lower forming wheel, and the cable core (15) and the pure aluminum strip (16) enter between the upper forming wheel and the lower forming wheel together to be extruded and formed into an aluminum strip; the coating module comprises at least one group of horizontal wheels, and the aluminum strip enters the group of horizontal wheels to be coated into an aluminum tube;
the welding induction mechanism (13) is arranged on the discharging side of the forming mechanism (12); the welding induction mechanism (13) comprises a connecting rod (1301) and an induction coil (1302) which are welded together;
the cable core (15) and the pure aluminum strip (16) are formed into the tubular aluminum strip through the forming mechanism (12), the tubular aluminum strip penetrates through an induction coil (1302) of the welding induction mechanism (13), and under the condition that the welding induction mechanism (13) is electrified, the tubular aluminum strip is continuously welded through electromagnetic induction by the induction coil (1302).
2. The aluminum sheath helium-free welding apparatus of claim 1, wherein: the molding mechanism (12) further includes a support module that supports the extrusion module and the cladding module.
3. The aluminum sheath helium-free welding apparatus of claim 2, wherein: the support module comprises a front bracket (1211), a mounting plate and a rear bracket (1213), wherein the front bracket (1211) and the rear bracket (1213) are respectively arranged on two sides of the mounting plate; the extrusion module and the coating module are arranged on the mounting plate.
4. The aluminum sheath helium-free welding apparatus of claim 1, wherein: the forming mechanism (12) further comprises a guide pulley (1209), and the guide pulley (1209) is arranged on the feeding side of the forming mechanism (12).
5. The aluminum sheath helium-free welding apparatus of claim 1, wherein: the molding mechanism (12) further comprises a wire pressing wheel (1207), and the wire pressing wheel (1207) is arranged between the extrusion module and the coating module.
6. The aluminum sheath helium-free welding apparatus of claim 1, wherein: the forming mechanism (12) further comprises a height adjusting module, and the height of the coating module is adjusted by the height adjusting module to be matched with the height of the welding induction mechanism (13); the height adjusting module comprises a lifting nut (1214), a lifting base (1215) and a lifting screw (1216), the lifting screw (1216) is fixed in the lifting base (1215), the lifting screw (1216) supports the coating module, and the position of the lifting nut (1214) on the lifting screw (1216) is adjusted, so that the height of the coating module is adjusted.
7. The aluminum sheath helium-free welding apparatus of claim 1, wherein: the device comprises a forming mechanism (12), and is characterized by further comprising a first belt passing device (7), a first belt arranging device (8), a trimming device (9), a second belt passing device (10) and a second belt arranging device (11) which are arranged before feeding of the forming mechanism (12), wherein the first belt passing device (7) conveys the pure aluminum belt (16), the first belt arranging device (8) shapes the pure aluminum belt (16), the trimming device (9) trims the pure aluminum belt (16), the second belt arranging device (10) conveys the cable core (15), and the second belt arranging device (11) shapes the cable core (15).
8. The utility model provides an aluminium sheath does not have helium and welds production line which characterized in that: the aluminum sheath helium-free welding device comprises a cable core pay-off rack (1), a first wire passing rack (2), a pure aluminum strip pay-off rack (3), an aluminum strip tension control device (4), a second wire passing rack (5), an aluminum strip edge cutting waste wire take-up reel (6) and the aluminum sheath helium-free welding device as claimed in any one of claims 1 to 7; the cable core pay-off rack (1) unreels a cable core (15), the first wire passing rack (2) conveys the cable core (15), the pure aluminum tape pay-off rack (3) unreels a pure aluminum tape (16), and the aluminum tape tension control device (4) and the second wire passing rack (5) convey the pure aluminum tape (16); the aluminum sheath is pressed by a helium welding-free device, wraps the cable core (15) and the pure aluminum tape (16) and is welded to form the aluminum sheath.
9. An aluminum sheath helium-free welding method using the aluminum sheath helium-free welding apparatus as set forth in any one of claims 1 to 7, characterized by comprising the steps of:
s1, respectively conveying a cable core (15) and a pure aluminum tape (16) into the aluminum sheath helium-free welding device;
s2, carrying out pre-treatment of shaping and trimming on the cable core (15) and the pure aluminum strip (16);
s3, the cable core (15) in the step S2 is sleeved in the pure aluminum strip (16) in the step S2 in a penetrating mode, and the cable core (15) and the pure aluminum strip (16) are extruded and wrapped to obtain a tubular aluminum strip;
and S4, the tubular aluminum strip penetrates through an induction coil (1302) of the welding induction mechanism (13), the welding linear velocity and the welding voltage coefficient of the welded aluminum pipe are controlled, and the tubular aluminum strip is welded in an induction mode to obtain the aluminum sheath.
10. The aluminum sheath helium-free welding method of claim 9, wherein: in step S4, the welding linear velocity and the welding voltage coefficient are synchronously adjusted, the welding linear velocity is 5.5m/min-50.5m/min, and the welding voltage coefficient is 55.5% -95.5%.
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| GB854062A (en) * | 1957-06-07 | 1960-11-16 | Magnetic Heating Corp | Improvements relating to tube or cable sheath welding |
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| CN111952014A (en) * | 2020-09-02 | 2020-11-17 | 江苏亨通线缆科技有限公司 | Production system of aluminum sheath cable |
| CN112071519A (en) * | 2020-09-02 | 2020-12-11 | 江苏亨通线缆科技有限公司 | Processing method of aluminum sheath cable |
| CN213672357U (en) * | 2020-11-17 | 2021-07-13 | 成都轩延智能装备有限责任公司 | Argon arc welding cable production line with automatic weld tracking system |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA637355A (en) * | 1962-02-27 | R. Carpenter Floyd | Process for making aluminum sheathed cable | |
| GB854062A (en) * | 1957-06-07 | 1960-11-16 | Magnetic Heating Corp | Improvements relating to tube or cable sheath welding |
| CN101140819A (en) * | 2007-07-25 | 2008-03-12 | 通鼎集团有限公司 | Cable aluminum sheath extrusion welding device |
| CN102266999A (en) * | 2011-08-01 | 2011-12-07 | 江苏亨通线缆科技有限公司 | Process for manufacturing railway signal cable |
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