Research On The Design And Related Technology Of Membrane Wall Welding Machine

Membrane wall tube screen is the main pressure part of boilers, which is often formed by the welding method. But in the process of welded tube screen, welding contraction deformation is inevitable. Boiler manufacturing enterprises have been plagued by difficulties in reducing the deformation and improving the quality of tube screen welding. Therefore, it is very important to develop a kind of membrane wall welding machine with simple structure, good welding quality, stable performance and high efficiency.First, in this paper, the welding automation and welding numerical simulation technology have been studied. On this basis, According to engineering technical requirements of membrane wall tube screen, welding procedure has been studied and reasonable welding method has been determined. And then, the membrane wall welding machine which can fit welding procedure requirement of tube screen has been designed. After that general design of the whole machine, clamp and convey mechanism of the tube screen, transmission mechanism and welding torch adjusting mechanism have been finished.Secondly, combining with numerical simulation technology and reverse deformation, the roller spacing has been determined. In this paper, the tube screen sample has been numerically simulated and experimented. Feasibility and veracity of the numerical simulation in analysis of welding shrinkage is verified by comparing numerical simulation results with welding experiment results. And then, this method has been applied to the design of welding machine. That is, the tube screen shrinkage deformation has been got by simulating the actual working condition of the membrane wall welding machine welding the tube screen. In the end, the compensation value of roller spacing has been defined.Finally, the main components of the welding machine have been analyzed by finite elements software. In order to obtain the safety factor of the roller and ensure it has enough service life, the roller and the tube in the clamp and convey mechanism of the tube screen have been analyzed. For the sake of guaranteeing safety and reliability, a strength of the roller shaft verification has been carried out.In the design process of the welding machine, the numerical simulation technology used sufficiently. That can both reduce the cycle of the welding machine research and save the development cost, also ensure the welding quality and welding efficiency of tube screen.