【Yunkang welding supply edit】

   The welding roller frame is an important welding auxiliary device, which plays a key role in the field of welding. Its working principle is mainly to use the friction between the weldment and the active roller to drive the cylindrical (or conical) weldment to rotate, thereby realizing displacement, and can perform horizontal welding of the inner and outer circumferential seams and inner and outer longitudinal seams of the workpiece. When used in conjunction with automatic welding equipment, it can greatly improve welding efficiency and quality, so it is called a welding helper by users.

    For example, in the welding production process of special vehicles, tank welding is inseparable from the welding roller frame. The welding roller frame is usually composed of an active frame and a driven frame, which is easy to move and can be directly placed on the workshop floor for use. The active and driven frames use steel plate structure brackets with good comprehensive performance and large load-bearing capacity. The base is stress-relieved after welding, and it will not deform even after long-term use.

    The surface of the roller is inlaid with vulcanized rubber made by a special vulcanization process, which can not only meet the ability to carry workpieces, but also protect the workpieces. It has a large load-bearing capacity and good wear resistance and anti-aging performance, and is not easy to debond. The swing arm of the self-aligning roller frame can adapt to workpieces of different diameters, and the rotary axis has strong rigidity to ensure that the workpiece can be opened at a suitable angle when placed on the roller assembly.

    The four rollers of the active frame are fully meshed, and the transmission gear and the drive reducer are connected as a "cross" coupling. The transmission is reliable, the torque transmitted is large, and the slight difference in axiality can be compensated appropriately. All transmission gears are made of high-quality steel and are surface-hardened, with high hardness and wear resistance. The welded roller frame is driven by a worm gear reducer, which has high synchronization performance, so that the rollers can run synchronously, effectively preventing early damage to the reducer and extending the service life.

    The use of welding rollers is of great significance for improving weld quality, reducing labor intensity and improving work efficiency. It is widely used in the assembly and welding of cylinders. It can also be used for the assembly and welding of vertebral bodies, segmented unequal diameter rotating bodies, and the assembly and welding of non-circular long weldments. In combination with manual welding, it can also be used as equipment for detecting and assembling cylindrical workpieces.

Assembly method of welding roller frame

(I) Preparation before installation

    Before installing the welding roller frame, it is very important to build the equipment foundation. The concrete foundation is the guarantee for the stable operation of the roller frame, and the normal curing period of the concrete must be guaranteed. Generally speaking, the curing time needs to be determined according to the specific environmental conditions and concrete mix ratio, usually not less than 7 days. Only a fully cured concrete foundation can ensure its strength and stability and provide solid support for the roller frame. At the same time, it is necessary to ensure that the installation position of the equipment is on the same horizontal line. This can be measured and adjusted by professional measuring tools such as a level to ensure that the error is within the allowable range, generally not exceeding ±2mm. This ensures that the roller frame will not tilt during operation, thereby ensuring the accuracy and quality of the welding work.

(II) Installation steps

    1. When arranging the roller rack, pay strict attention to the laying length of the roller and the main pipe. According to the size requirements of different types of welding roller racks and workpieces, reasonably determine the laying length to ensure that the workpiece can be placed on the roller steadily and rotate smoothly during the work process. At the same time, it is key to keep the base parallel to the ground, which can be achieved by adjusting the support feet of the base or using gaskets. Before placement, thoroughly clean the bottom to prevent impurities from mixing in, as impurities may affect the stability and running accuracy of the roller rack. For example, if impurities such as pebbles are sandwiched between the base and the ground, it may cause the roller rack to shake during operation.

    2. When installing the universal wheel, clamp the roller according to the gear mouth of the bracket to ensure a firm installation. Then rotate 90 degrees clockwise to tighten it, so that the universal wheel will not loosen during the work process. During the installation process, pay attention to check the flexibility and smoothness of the universal wheel. If there is a jam or inflexibility, the universal wheel should be adjusted or replaced in time.

    3. When debugging and fixing the welding roller rack bracket, keep the bracket vertical. You can use a plumb line or professional measuring tools to check to ensure that the angle deviation between the bracket and the ground does not exceed ±1°. Use the fine-tuning handle to adjust the bracket angle. According to the actual work requirements and the shape and size of the workpiece, accurately adjust the bracket angle to achieve the best welding effect. Install the steel structure connector correctly, tighten the outside with a 24mm six-nut, and ensure that the connector is firmly installed and can withstand the weight of the workpiece and various forces during the welding process.

(III) Installation precautions

    1. The self-adjusting roller frame should be installed in a sturdy, ventilated, rainproof, moisture-proof, dust-proof place, and away from severe vibration and bumps. This can ensure the normal operation of the equipment and extend the service life of the equipment. For example, installing it on a solid ground can reduce the vibration of the equipment during operation, a well-ventilated place can ensure the heat dissipation of the equipment, and rainproof, moisture-proof and dustproof can prevent the equipment from being affected by the external environment. It is strictly forbidden to spray corrosive liquids on the equipment, because corrosive liquids may damage the surface coating and internal components of the equipment.

    2. When the master and slave roller frames are installed at the same time, it must be ensured that the master and slave frames are horizontal and the center lines are on the same straight line. The diagonal line of the master and slave frames can be measured for adjustment to ensure that the diagonal lengths are equal and the error does not exceed ±5mm. This ensures that the workpiece will not tilt during rotation, thereby ensuring the welding quality.

    3. The placement of the workpiece requires strict implementation in accordance with the design regulations, and the diameter and weight of the workpiece should be within the load range of the equipment. Otherwise, safety accidents are prone to occur. According to the length of the equipment, the distance between the main and auxiliary wheels should be adjusted appropriately to ensure that the workpiece can be placed on the rollers smoothly and rotate smoothly. For example, for workpieces with larger diameters, the distance between the main and auxiliary wheels should be appropriately increased to ensure the stability of the workpiece.

    4. The rubber wheel is only suitable for working at room temperature. In special cases, the maximum temperature of the workpiece in contact with the rubber wheel is not allowed to be higher than 75 degrees. Because high temperature may cause damage to the rubber wheel and affect the normal operation of the equipment. During the work process, pay close attention to the temperature changes of the rubber wheel. If there is any abnormality, stop working in time and check it.

    5. When in use, the roller should be in contact with the workpiece, and it is strictly forbidden to contact with the weld or sharp parts. This can prevent the roller from being damaged and ensure the normal operation of the equipment. At the same time, when hanging the workpiece, it is strictly forbidden to hit the roller to prevent damage to the roller or other parts. When the equipment is not fixed, a strong impact is likely to cause the whole machine to overturn, causing serious safety accidents.

    6. Adjust the roller frame from low speed to high speed gradually at startup, so as to avoid the motor from being overloaded instantly and extend the service life of the motor. When changing the direction, the motor can only be switched after it stops, otherwise it is easy to cause the motor to burn out. During operation, it is strictly forbidden to separate the man and the machine, and it is strictly forbidden to stand within the rotation radius of the workpiece to ensure the safety of personnel.

    7. In order to ensure the performance of the equipment, all transmission parts should be filled with sufficient lubricating oil before use. This can reduce the wear of the transmission parts and extend the service life of the equipment. The equipment should fill in the daily inspection and maintenance record form, and the whole machine should be inspected regularly after a period of use, and the inspection record form should be filled in to timely discover and solve the problems of the equipment.

    8. The equipment uses AC power, and the power supply line must pass through the air switch for safe operation. When debugging the equipment, turn on the power, press the start button, and observe the rotation of the driving wheel. Check whether the speed adjustment is normal. If there is any abnormality, the power should be turned off immediately to find the cause. Only after the fault is eliminated can the machine be powered on again for testing.

    9. Check and remove obstacles on this equipment before use, and someone must use and keep it. This can ensure the safe operation of the equipment and avoid obstacles affecting the normal operation of the equipment. The roller frame parts (rubber wheels) should not come into contact with oils and fire, because oils may damage rubber wheels and fire may cause fires and other safety accidents.

Process application of welding roller rack

(I) Main application fields

As welding auxiliary equipment, the roller rack plays an important role in many industrial welding fields. In cylindrical assembly and welding, it can drive the cylindrical workpiece to rotate, making the welding work more convenient and efficient. By adjusting the height of the master and slave rollers, the assembly and welding of the vertebral body and the segmented unequal diameter rotating body can also be performed. For some non-circular long weldments, they can be clamped in a special annular clamp, and the welding operation can also be performed on the welding roller rack. In addition, the welding roller rack can also be used as a detection equipment in conjunction with manual welding to detect cylindrical workpieces to ensure that the quality of the workpiece meets the requirements.

(II) Application in different industries

    In the wind power industry, welding rollers are widely used in the welding of wind turbine towers. For example, a self-adjusting roller for welding wind turbine towers supports the tower through a supporting structure, a lifting assembly and a calibration assembly. After the calibration is completed, the two ends of the tower are adjusted to a suitable height by a servo motor for welding, with a low error rate and a fast docking speed.

    In the pressure vessel industry, self-adjusting welding rollers and adjustable welding rollers can automatically adjust according to tanks of different diameters to ensure the stability of the welding process. During the manufacturing process, welding rollers can improve the quality of welds and meet the high requirements of pressure vessels for sealing and safety.

    In the petrochemical industry, welding rollers are used for welding of various pipelines and containers. Pipes and containers have various shapes, and welding rollers can adapt to different workpiece sizes and shapes to improve welding efficiency. For example, the automatic adjustment roller bearing can be adjusted according to the diameter of the cylinder, which is suitable for welding of petrochemical equipment of different specifications.

    In the pipeline industry, welding rollers can realize horizontal welding of inner and outer circumferential seams and inner and outer longitudinal seams of pipelines. With automatic welding equipment, the quality of welds can be greatly improved and labor intensity can be reduced. At the same time, for pipes of different diameters, the roller spacing can be adjusted through the adjustable welding roller frame to meet various welding needs.

    In the steel structure industry, the roller spacing and speed are adjusted according to the size of different components to improve the accuracy and efficiency of welding. For example, the speed controller of the adjustable welding roller frame can achieve stepless speed change, and the linear speed of the workpiece rotation is 6-60 meters/hour, which can meet the needs of various welding such as manual welding, automatic surfacing, and automatic submerged arc welding.

    So, by explaining the application of roller frames in different industries, do you think the roller frame can bear the title of "welding assistant"?