The present invention relates to the field of plastic forming equipment for shaft parts, and more particularly to a large-scale axle intelligent cross wedge rolling mill for rail transit.
Large-scale axles are core components in high-speed rail, rail transit, large-scale construction machinery and other fields, and are increasingly needed. The traditional preparation method of large-scale shaft parts includes a step of forgoing by fast forging machines and precision forging machines. The fast forging process requires human intervention, is long in production cycle, low in product accuracy, high in energy consumption, and low in efficiency. Its subsequent production process requires heavy cold processing, which greatly destroys the metal streamlines on the surface of the product and reduces the mechanical properties of the product while the amount of cutting is large. The precision forging machine is completely monopolized by foreign companies. Moreover, the forging speed is able to be above doubled than the fast forging speed and the amount of cutting is effectively reduced, but it still takes at least 4 minutes to prepare an axle. The subsequent processing loss and product mechanical properties are still not improved, the equipment input and output are relatively low, and the quality stability is poor.
Cross wedge rolling is an efficient and clean plastic forming technology for parts. Compared with existing production methods, it has some advantages as follows. (1) The production efficiency is increased by 2 to 3 times. (2) The material saving rate is increased by 10 to 25%. (3) The product precision is high, and machining procedures are reduced. (4) No impact and low noise. (5) The production cost is reduced by about 30%. Take the production of train RD2 axles as an example: the preparation time of a single axle is reduced from 10 minutes to 1 minute, the production efficiency is increased by 3 to 5 times, the material saving is 50-100 Kg, and the material saving rate is increased by 10-20%. Therefore, the use of cross wedge rolling technology to prepare large-scale axles for rail transit not only improves the efficiency and accuracy of axle forming, but also improves the axle life due to the retention of hot-worked metal streamlines.
At present, the largest cross wedge rolling mill in the world is only able to roll large-scale shafts with a diameter of 150 mm and a length of 1200 mm or less. For large-scale shaft products with a diameter in a range of 200-250 mm and a length in a range of 2000-2800 mm used in high-speed rail, rail transit, large-scale construction machinery and other fields, the overall design and the critical structure reliability of the radio equipment are required. Moreover, rolling mill molds are relatively large in size and weight, and the existing cross wedge rolling devices are unable to meet the needs of efficient preparation of large-scale axles in terms of structural type and mold replacement method. At the same time, it is impossible to dynamically monitor the working status of the rolling mill, and it is difficult to fully grasp the service life and working effect of the device. Accordingly, it is very important to adopt the certain structure and method to solve the above problems. Therefore, a new type of intelligent cross wedge rolling mill needs to be proposed for overcoming the above problems.
In the design process of the traditional cross wedge rolling mill, due to the small rolling force, the traditional cross wedge rolling mill is small in size and high in reliability, and the corresponding die is also small in weight and size, so that There is no risk of equipment being easily damaged. However, for large-scale axle cross wedge rolling mill, because the diameter of the roller is 1800 mm, the maximum of the rolling force reaches 820 tons, and the maximum width of the die reaches 2900 mm, the mill has high power requirements and it is difficult to determine whether each key structure and function meets the production requirements. If the traditional structure is still adopted, the use effect of the large-scale axle cross wedge rolling mill will be greatly affected.
Aiming at the above problems, the present invention provides a large-scale axle intelligent cross wedge rolling mill for rail transit.
The present invention provides technical solutions as follows.
A large-scale axle intelligent cross wedge rolling mill for rail transit comprises a main transmission device, a memorial arch unit, two worm-gear pressing devices, a roll assembly and two guide devices, wherein:
the main transmission device comprises a main drive motor, a primary reducer and a transfer case, wherein an output shaft of the main drive motor is connected with an input shaft of the primary reducer, an output shaft of the primary reducer is connected with an input shaft of the transfer case, two output shafts of the transfer case are connected with an upper transmission shaft and a lower transmission shaft through two universal couplings, respectively, the two output shafts of the transfer case rotate in a same direction;
the memorial arch unit comprises a left memorial arch, a right memorial arch, an I-beam for connecting a lower end of the left memorial arch with a lower end of the right memorial arch, and two C-shaped beams for connecting an upper end of the left memorial arch with an upper end of the right memorial arch, wherein the C-shaped beams are used to give way for lifting out and replacing a roller;
the two worm-gear pressing devices are installed at the upper end of the left memorial arch and the upper end of the right memorial arch, respectively;
the roll assembly comprises two upper bearing seats and two lower bearing seats, wherein:
the two guide devices are located at a front side and a rear side of the memorial arch unit.
Preferably, the external side of the one end of the upper slide shaft and that of the lower slide shaft are connected with two connection sleeve bodies through screws, respectively; two connection sleeve end covers are connected with the two connection sleeve bodies through screws, respectively; two opposite surfaces of the two connection sleeve bodies and the two connection sleeve end covers have two installation slots and two limit slots, respectively; the two connection sleeve bodies and the connection sleeve end covers form two connection sleeves, respectively; the two end portions of the two piston rods of the two clamping hydraulic cylinders are rotatably connected with the two connection sleeves, respectively; two bearings are provided between the two installation slots and the two piston rods of the two clamping hydraulic cylinders, respectively; two circular limit blocks which match with the two limit slots are provided on the two piston rods of the two clamping hydraulic cylinders, respectively.
Preferably, two first positioning hooks are integrated with the two lower shaft necks, respectively for positioning the lower roller; a left side and a right side of the lower roller have two first positioning surfaces which are corresponding to the two first positioning hooks, respectively; the two first positioning surfaces have two first hook grooves which match with the two first positioning hooks, respectively; the two upper shaft necks have two second positioning surfaces for positioning the upper roller, two second positioning hooks are located at a left side and a right side of the upper roller and are corresponding to the two second positioning surfaces, respectively, the two second positioning surfaces have two second hook grooves which match with the two second positioning hooks, respectively.
Preferably, four guide keys are located at a middle portion of two inner side end surfaces of the two upper and lower shaft necks along a vertical direction, respectively; all of two side faces of the upper roller and two side faces of the lower roller have four guide grooves which match with the guide keys, respectively.
Preferably, all of the two inner side surfaces of the two upper shaft necks and the two inner side surfaces of the two lower shaft necks have four first horizontal slots, respectively; all of the two side faces of the upper roller and the two side faces of the lower roller have four second horizontal slots which are communicated with the four first horizontal slots, respectively; four strengthen keys are inserted into the four first horizontal slots and the four second horizontal slots, respectively, so as to improve a torque transmission capacity between the two lower shaft necks and the lower roller, the two upper shaft necks and the upper roller; each of the four strength keys is fixedly connected with an adjacent lower shaft neck and the lower roller, or is fixedly connected with an adjacent upper shaft neck and the upper roller through screws.
Preferably, all of two side walls of an upper roller and two side walls of a lower roller have multiple first rectangular through holes circumferentially evenly provided therein; all of the two upper shaft necks and the two lower shaft necks have multiple second rectangular through holes, wherein the multiple first rectangular through holes are communicated with the multiple second rectangular through holes one to one, respectively; multiple T-shaped bolts are inserted between the multiple first rectangular through holes and the multiple second rectangular through holes, respectively; two fixture blocks are provided at an inner side of each of the multiple first rectangular through holes and are symmetrical to each other with respect to a diagonal line of the each of the multiple first rectangular through holes, in such a manner that after an T-shaped end portion of each of the multiple T-shaped bolts is inserted into one of the multiple second rectangular through holes, which is communicated with the each of the multiple first rectangular through holes, and is rotated by 90 degrees, the each of the multiple T-shaped bolts is stuck between the two fixture blocks to avoid rotation; another end portion of the each of the multiple T-shaped bolts penetrates through the one of the multiple second rectangular through holes and is threadedly connected with a nut; while disassembling the upper roller and the lower roller, the T-shaped bolts are loosened and reversely rotate by 90 degrees, so that the T-shaped bolts are quickly pulled out.
Preferably, two axial movement devices, which are respectively located at an external side surface of the two lower bearing seats, comprises two slider seats fixed on an external side of the two lower bearing seats through bolts;
the two protective cases are provided at an external end surface of the two slider seats, respectively;
two of the four separation sleeves corresponding to the two lower bearing seats, the lower bearing seats, the two slider seats and four of the eight bearing end covers corresponding to the two lower bearing seats are respectively connected with each other as a whole through four of the limit rings corresponding to the two lower bearing seats, so that the movement of the roll assembly and the axial sliding of the lower slide shaft do not interfere with each other;
two inclined sliders are provided at a front side and a rear side of each of the two slider seats, respectively;
the two inclined sliders are slidably provided within an inclined slide slot of a movement adjustment block, the movement adjustment block is moved up and down to push or compress the two inclined sliders for further axially moving the each of the lower bearing seats;
a limit slider is provided at a side of the movement adjustment block which is close to the left memorial arch or the right memorial arch, the left memorial arch or the right memorial arch has a limit slide slot which matches with the limit slider;
one end of a movement hydraulic cylinder is hinged with a lower end of the movement adjustment block, another end of the movement hydraulic cylinder is hinged with the left memorial arch or the right memorial arch, so as to drive the movement adjustment block to move up and down;
a first lock ramp slider and a lock block is provided at an external side of the movement adjustment block, a second lock ramp slider which is corresponding to the first lock ramp slider is provided on the lock block, the movement adjustment block is locked through the second lock ramp slider compressing the first lock ramp slider;
the lock block has multiple lock slide slots, both the left memorial arch and the right memorial arch have multiple lock bolts which match with the multiple lock slide slots, respectively, so as to limit the lock block to slide along the lock slide slots;
one end of a locking hydraulic cylinder is hinged with a lower end of the lock block, another end of the locking hydraulic cylinder is hinged with the memorial arch unit.
Preferably, two dovetailed limit blocks are provided at a middle portion of an upper end surface of the two lower bearing seats, respectively; two prestressed plates are located above the lower bearing seats, respectively; a lower surface of the two prestressed plates has two dovetailed slots which matches with the two dovetailed limit blocks, respectively; two prestressed seats are provided at a front end and a rear end of an upper surface of each of the two prestressed plates, respectively; two prestressed threaded rods are provided within and threadedly connected with the two prestressed seats, respectively;
an upper portion of the two prestressed threaded rods has two limit grooves, respectively; two connection covers are inserted into the two limit grooves, and are fixedly connected with two connection blocks which are provided on a lower surface of the two upper bearing seats through screws, respectively; the two connection blocks are fixedly connected with the two upper bearing seats, respectively; two first pressure sensors are provided between the two prestressed threaded rods and the two connection blocks for detecting the prestressed force, respectively; two creepmeters are inserted into the left memorial arch and the right memorial arch for detecting deformation thereof, respectively.
Preferably, each of the two guide devices comprises two installation seats, wherein the two installation seats are fixed on the left memorial arch and the right memorial arch, respectively;
a tie rod is installed between the two installation seats for applying a transverse prestressed force between the left memorial arch and the right memorial arch;
a guide plate seat is sleeved on the tie rod;
two hinge ears are provided at a left end and a right end of an external side of the guide plate seat, respectively;
two guide hydraulic cylinders are hinged with the two hinge ears, respectively; an upper end of the two guide hydraulic cylinders are hinged with the left memorial arch and the right memorial arch, respectively;
an upper surface of the guide plate seat has a guide slot; the guide slot and the two hinge ears are provided at two sides of the tie rod, respectively;
a guide plate is inserted into the guide slot, the guide plate seat is connected with the guide plate through bolts, the guide plate has multiple bolt slide slots therein, a bolt limit block is rotatably installed at a middle portion of an external side of the guide plate, the bolt limit block is fixedly connected with an end portion of a fastening bolt, the fastening bolt is threadedly connected with an external side wall of the guide slot, two spacers are provided between the guide plate and the external side wall of the guide slot, respectively, the two spacers are connected with the guide plate seat through screws, two second pressure sensors are provided between the two spacers and the guide plate, respectively, a guide bar is connected with an inner side of the guide plate through bolts.
Preferably, four fixed frames are provided at an upper surface and a lower surface of a left side and a right side of the guide plate seat, respectively, a side surface of the fixed frames is connected with the left memorial arch or the right memorial arch through screws for enhancing a stability of the guide plate seat in a rolling process.
Compared with the prior art, the present invention has advantages as follows.
(1) In the present invention, two lower shaft necks are detachably connected with the left end surface and the right end surface of the lower roller, respectively; two upper shaft necks are detachably connected with the left end surface and the right end surface of the upper roller, respectively, so that the quick disconnection of the upper and lower rollers with the upper and lower shaft necks is able to be achieved, so as to quickly operate and install the roll to meet the requirement of quick mold replacement, thus improving the flexibility of rolling.
(2) In the present invention, the roll mold is able to be quickly replaced in accordance with the product rolling specification, and the replacement time is able to be reduced from the traditional 2 days to 0.5 days, which meets the requirements of rolling time for products with different specifications.
(3) The clamping hydraulic cylinder provided by the present invention is able to increase a certain axial force in the rolling process of axle, which effectively eliminates the axial movement caused by rolling bearing clearance and machining errors, and avoids the asymmetry of the upper and lower molds due to the above factors, thereby improving the overall size and accuracy of products.
(4) The present invention is able to realize dynamic monitoring and adjustment of rolling force, prestress, guide plate force and roll transverse force, so as to realize intelligent control of large-scale axle wedge rolling process.
In the drawings, 1: main transmission device; 2: memorial arch unit; 3: worm-gear pressing device; 4: roll assembly; 5: guide device; 101: main drive motor; 102: primary reducer; 103: transfer case; 104: universal coupling; 201: left memorial arch; 202: right memorial arch; 203: I-beam; 204: C-shaped beam; 401: upper bearing seat; 402: lower bearing seat; 403: clamping sleeve; 404: upper transmission shaft; 405: upper slide shaft; 406: lower transmission shaft; 407: lower slide shaft; 408: upper shaft neck; 409: lower shaft neck; 410: clamping hydraulic cylinder; 411: protective case; 412: bearing end cover; 413: connection sleeve body; 414: connection sleeve end cover; 415: installation slot; 416: limit slot; 417: circular limit block; 418: first positioning hook; 419: first positioning surface; 420: second positioning surface; 421: second positioning hook; 422: guide key; 423: guide groove; 424: first horizontal slot; 425: second horizontal slot; 426: strengthen key; 427: first rectangular through hole; 428: second rectangular through hole; 429: T-shaped bolt; 430: fixture block; 431: slider seat; 432: inclined slider; 433: movement adjustment block;
434: limit slider; 435: limit slide slot; 436: movement hydraulic cylinder; 437: first lock ramp slider; 438: lock block; 439: second lock ramp slider; 440: lock slide slot; 441: lock bolt; 442: locking hydraulic cylinder; 443: dovetailed limit block; 444: prestressed plate; 445: dovetailed slot; 446: prestressed seat; 447: prestressed threaded rod; 448: limit groove; 449: connection cover; 450: connection block; 451: lower roller; 452: upper roller; 453:
inclined slide slot; 454: separation sleeve; 455: limit ring; 456: first hook groove; 457: second hook groove; 458: first pressure sensor; 459: creepmeter; 460: labyrinth cover; 461: positioning sleeve; 501: installation seat; 502: tie rod; 503: guide plate seat; 504: hinge ear; 505: guide hydraulic cylinder; 506: guide slot; 507: guide plate; 508: guide bar; 509: bolt slide slot; 510: bolt limit block; 511: fastening bolt; 512: spacer; 513: fixed frame; 514: second pressure sensor.
The present invention is further explained in detail with reference to embodiments as follows.
A large-scale axle intelligent cross wedge rolling mill for rail transit comprises a main transmission device 1, a memorial arch unit 2, two worm-gear pressing devices 3, a roll assembly 4 and two guide devices 5, wherein:
the main transmission device 1 comprises a main drive motor 101, a primary reducer 102 and a transfer case 103, wherein an output shaft of the main drive motor 101 is connected with an input shaft of the primary reducer 102, an output shaft of the primary reducer 102 is connected with an input shaft of the transfer case 103, two output shafts of the transfer case 103 are connected with an upper transmission shaft 404 and a lower transmission shaft 406 through two universal couplings 104, respectively;
the memorial arch unit 2 comprises a left memorial arch 201, a right memorial arch 202, an I-beam 203 for connecting a lower end of the left memorial arch 201 with a lower end of the right memorial arch 202, and two C-shaped beams 204 for connecting an upper end of the left memorial arch 201 with an upper end of the right memorial arch 202, wherein the C-shaped beams 204 are configured to roll replacement;
the two worm-gear pressing devices 3 are installed at the upper end of the left memorial arch 201 and the upper end of the right memorial arch 202, respectively;
the roll assembly 4 comprises two upper bearing seats 401 and two lower bearing seats 402, wherein:
the two guide devices 5 are located at a front side and a rear side of the memorial arch unit 2, wherein:
The working principle of the present invention is described as follows. When the mold needs to be replaced, the T-shaped bolts 429 are loosened, rotated by 90 degrees and then quickly taken out; and then the strengthening keys 426 are removed for separating the upper shaft necks 408 from the upper roller 452, and separating the lower shaft necks 409 from the lower roller 451, respectively; and then the upper roller 452 is lifted out; after lifting out the upper roller 452, the guide hydraulic cylinders 505 are stretched out for turning over the guide plate seat 503 by 90 degrees, so as to complete the assignment; and then the lower roller 453 is lifted out, so that both the upper roller 452 and the lower roller 451 are removed. After the mold is replaced, the reverse operation is performed, both the upper roller 452 and the lower roller 451 are reinstalled into the rolling mill; when the guide bar 508 needs to be replaced, the spacers 512 are firstly removed, and then the fastening bolts 511 are twisted to pull the guide plate 507 back till the guide plate 507 does not collide with the upper roller 452 while being turned over; and then the guide hydraulic cylinders 505 are stretched out for turning over the guide plate seat 503 by 90 degrees, so that the guide plate 507 is turned out, thus the guide bar 508 is disassembled and replaced.
The main features and advantages of the present invention are shown and described above. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above-mentioned exemplary embodiments. Moreover, the present invention is able to be achieved in other specific forms without departing from the spirit or basic characteristics of the present invention. Accordingly, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The protective scope of the present invention is defined by the appended claims rather than the foregoing description. Therefore, all changes falling within the meaning and scope of equivalent elements of the claims are included in the present invention.
In addition, it should be understood that although this specification is described in accordance with the embodiments, not each embodiment only includes an independent technical solution. The description in the specification is only for clarity, and those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementations that can be understood by those skilled in the art.
Number | Date | Country | Kind |
---|---|---|---|
202110183803.5 | Feb 2021 | CN | national |
This is a Continuation Application of the International Application PCT/CN2021/080676, filed on Mar. 15, 2021, which claims the benefit of CN 202110183803.5 and priority date of Feb. 8, 2021.
Number | Date | Country | |
---|---|---|---|
Parent | PCT/CN2021/080676 | Mar 2021 | US |
Child | 17575121 | US |