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利用高效拋丸器拋出的高速彈丸流束擊碎鋼管內(nèi)表面上的氧化皮、銹層及其雜物，使之獲得精細的光亮表面，提高工件的抗拉和抗壓強度，為內(nèi)表面涂漆保護增加附著力，達到防腐、護管、延長鋼管使用壽命之目的。清理后工件表面表面的光潔度和粗糙度符合有關(guān)的標準規(guī)定。大口徑的鋼管使用內(nèi)壁拋丸機，鋼管內(nèi)壁拋丸處理線，主要包括
1 | 小拋丸器?small Impeller Head(X508-X870) |
2 | 拋丸器?large Impeller Head(X870-X1600) |
3 | 小拋頭回轉(zhuǎn)支撐機構(gòu)small Impeller Head?rotation carriage system |
4 | 拋頭驅(qū)動行走系統(tǒng)Impeller Head?transport system |
5 | 特型帶供丸系統(tǒng),With special belt abrasive supply system |
6 | 大拋頭回轉(zhuǎn)支撐機構(gòu)large Impeller Head?rotation carriage system |
7 | 液壓系統(tǒng) hydraulic system (German Rexroth?hydraulic system) |
8 | 斗式提升機Bucket Elevator |
9 | 分離器Air Separator |
10 | 移動密封室 moveable sealing room |
11 | 固定密封室 fixed sealing room |
12 | 螺旋輸送器Screw Conveyor |
13 | 上卸料輸送平車?charging and discharging flatca And drive system |
14 | 平臺護欄Platform Ladder |
15 | 彈丸控制系統(tǒng)Shot ball Control System |
16 | 小除塵系統(tǒng)Dust Collector System |
17 | 彈丸風力回收風機風量: 120000 m3/h ?????Air blower?capacity?for abrasive recovery: 120000 m3/h ?????風機功率：90kWPower of the fan：90kW |
18 | 電控系統(tǒng)Electronic Control System |
19 | 葉片Blade for Impeller |
20 | 分丸輪Distributor for Impeller |
21 | 定向套Contral Cage for Impeller |
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上圖移動密封室和固定密封室,為了提高彈丸的利用效率，減少對密封室體的磨損，室體設(shè)計制造牢固，并室體內(nèi)的護板安裝牢固。室體內(nèi)護板采用優(yōu)質(zhì)Mn13護板。
一??前言??Foreword
首先感謝您選擇QGN500-1200型鋼管內(nèi)壁拋丸除銹機，為了使您能夠了解設(shè)備的有關(guān)性能，請仔細閱讀此技術(shù)文件。
Fist of all Thanks for choosing QGN500-1200?type production line of anti-corrosion steel pipe workpiece inside the wall shot blast machine. Please read the operation instruction carefully in order to let you know the production line of its optimal performance.
鋼管內(nèi)壁拋丸清理液壓馬達輸送拋頭 ???????
2、拋丸頭
特制的液壓驅(qū)動鋼管內(nèi)壁拋丸器理論和實踐相結(jié)合
為進一步開發(fā)拋丸清理機的拋丸器，需要對拋丸流進行全面的分析，要從進入進給系統(tǒng)開始繼而到從定向套出口**由葉輪葉片拋出。青鑄公司作為拋丸技術(shù)的領(lǐng)頭者，已經(jīng)通過拋丸器優(yōu)化了拋丸流并為全新的下一代拋丸器打開了門路，是世界上首先使用高速照相技術(shù)得到如此成果的公司。我們作為其受益人從中受到很大的啟發(fā)。 | 為進一步開發(fā)拋丸清理機的拋丸器，需要對拋丸流進行全面的分析，要從進入進給系統(tǒng)開始繼而到從定向套出口**由葉輪葉片拋出。青鑄公司作為拋丸技術(shù)的領(lǐng)頭者，已經(jīng)通過拋丸器優(yōu)化了拋丸流并為全新的下一代拋丸器打開了門路，是世界上首先使用高速照相技術(shù)得到如此成果的公司。我們作為其受益人從中受到很大的啟發(fā)。 |
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該設(shè)備適合各種型號的鋼管內(nèi)壁清理。該機型廣泛應(yīng)用供暖和排污管道，以及石油天然氣輸送管道。具有高效，密封效果好，結(jié)構(gòu)緊湊，裝卸料方便，和較高自動化等特點。
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鋼管內(nèi)壁拋丸清理效果圖
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?特制的液壓驅(qū)動鋼管內(nèi)壁拋丸器
With purpose made hydraulic steel pipe inner wall shot blast wheel
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理論和實踐相結(jié)合 | |
為進一步開發(fā)拋丸清理機的拋丸器，需要對拋丸流進行全面的分析，要從進入進給系統(tǒng)開始繼而到從定向套出口**由葉輪葉片拋出。青鑄公司作為拋丸技術(shù)的領(lǐng)頭者，已經(jīng)通過拋丸器優(yōu)化了拋丸流并為全新的下一代拋丸器打開了門路，是世界上首先使用高速照相技術(shù)得到如此成果的公司。我們作為其受益人從中受到很大的啟發(fā)！ In order to further develop the turbine wheel in shot blast machines,comperehensive analysis is required of the flow of the abrasive,beginning with its entry into the feed system and continuing through to its exit from the control cage and final ejection via the turbine blades.QINGZHU company ,a leader in shot blast technology,has optimised the flow of abrasive through the turbine and made this the starting point for a completely new,next generation turbine.Schlick as a lender in blast technology is the first company in the world to use high-speed camera techniques to achieve this. | |
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丸粒從定向套到葉片的優(yōu)化傳遞，?在1000 fps拍攝 ????????Optimized?transfer of abrasive grains from the control cage to a turbine blade,filmed at 1000 fps | |
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丸粒的不均勻分布?橫跨葉輪葉片的寬度 | 丸粒的均勻分布?橫跨葉輪葉片的寬度 |
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在小范圍內(nèi)的低密度拋丸 | 大區(qū)域的高密度拋丸?通過丸粒的優(yōu)化分布 |
? ???????一方面，這種均勻地分布，在丸粒加速過程中明顯地提高了能量的利用。另一方面也明顯地提高了磨料流在工件表面上的功效。在擴大的區(qū)域中，密度和覆蓋度也有可觀的增加。 On the one hand,this even distnbution results in significantly higher energy utilization during acceleration of the abrasive.On the other,italso significantly increases the efficiency of the abrasive stream on the work piece surface.Inensity and degree of coverage increase considerably over an enlarged area.?? ??這種能量利用率的增加在用金屬薄板、Almen 測量片的測試以及葉輪葉片的磨損中都可以看到對比。 The results of this improved energy utilization can be seen in comparative testing using sheet metal pieces ,on Aimen measurement strips and also from turbine wear-and-tear. | |
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二 ?QGN500-1200鋼管專用拋丸清理機的用途
QGN500-1200?Steel pipe?inner wall appropriative shot?Blsast machine
???????????該設(shè)備適合各種型號的鋼管內(nèi)壁清理。該機型廣泛應(yīng)用供暖和排污管道，以及石油天然氣輸送管道。具有高效，密封效果好，結(jié)構(gòu)緊湊，裝卸料方便，和較高自動化等特點。
The machine is suitable for surface rust removal of all kinds of steel pipe?inner wall?. It is widely used in Heating and drainage pipelines and oil and gas pipelines?.It has the advantage of high productivity,good sealing effect,composition compactly,loading and unloading easy and high technology.
拋丸清理具有下述優(yōu)點：
Strong point of the shot blast machin
*?裝卸工件方便?????Loading and unloading easy
*?大大提高清理效率??High productivity
*?減輕清理工作的勞動強度??Less intensity of labor
*?減輕環(huán)境污染??Less environment pollution
*?設(shè)備維修及清潔方便,維護費用低????Ease of cleaning & maintenance and Maintenance costs low
三、鋼管內(nèi)壁拋丸機設(shè)備技術(shù)規(guī)范
u?噪聲:低于**/T8355-1996《機械行業(yè)標準》中規(guī)定的90dB（A）。
u?Noise: below 90dB(A), according to **/T8355-1996<
u?粉塵濃度排放標準 ?????????????????????≤80mg/m3
u?Dust density standard discharging ???????≤80mg/m3
u?工件進出口處，維修門、輥道軸與清理室接合處均系用特殊結(jié)構(gòu)與密封 ???材料，密封效果好，彈丸、粉塵不外溢，有利于提高除塵效果，改善了周邊的工作環(huán)境。
u?Adoping special structure and material sealing at the in-out gate of workpiece and connection of repairing door、roller and cleaning room, make the effect sealing good , shot ball、dust never fly out ,enhance the cleaning-dust effect, change the environment .
u?安全：按《**5545—91鑄造機械安全防護技術(shù)條件》、《**526—96鑄造設(shè)備安裝工程施工及驗收規(guī)范》等標準安裝制作。
u?Safety:install and facture according to <<**5545-91 foundry machinery safe protective technical standard>>、<<**526-96 foundry equipment intallation project and accepting standard>>.and so on.
3.3、設(shè)備操作維修
???????Operatation and repairing of equipment
u?先進的高效拋丸器維修更換易損件簡單，耐磨性好，使用壽命長。
u?Repairing Advanced high efficient impeller unit is easy,wear-resisting and longer life.
u?清理室內(nèi)護板用耐磨遮蓋包鑄螺母栓接，保護螺栓頭部不易損壞，拆裝維修方便，護板及螺母使用壽命長，維修量小。
u?The lining is fasten by wear-resisting covered screw cap in the cleaning room,so as to protect the head of screw to avoid damage,repack is convenient.life of lining and screw cap is longer,almost without repair.
u?采用國內(nèi)生產(chǎn)的優(yōu)質(zhì)電氣元件，操作使用簡單，運行靈敏可靠。
u?Adoping civil advanced electrical component, operate simply and run sensitively, stably.
3.3、設(shè)備技術(shù)參數(shù)
???Techinology parameter of the equipment
1．鋼管拋丸機主要用于去除鋼管內(nèi)表面的銹蝕及氧化皮，獲得一定粗糙度的金屬本色表面。
???Steel pipe inner wall shot blast machine serve as cleaning away the scale and rust,which can get the primitive surface with certain rough degree.
2.被清工件的主要參數(shù)?：
??Parameters of cleaned workpiece
2.1．長度（mm）?：?12000
?????Length(mm): ???12000
2.2．管徑（mm）: ￠500-1200
?????Diameter of the pipe ?￠500-1200
3.技術(shù)特征：
?????Technology Features:
3.1．具有一次性可以同時清理1根鋼管功能。
?????It can clean the 1 steel pipe at the same time .
3.2．清理速度范圍：0.5～3.5 m/min （根據(jù)管徑不同速度可無級調(diào)速）
?????Range of cleaning speed: 0.5～3.5 m/min (Stepless speed adjusted according to the diameter)
3.3．拋丸器拋丸量：≥300 －800kg/min
?????Shot quantity of the impeller unit: ≥300－800?kg/min
3.4．液壓站功率：≥110kW
Power of the hydraulic station: ≥110kW
3.5 ?拋丸器數(shù)量：2臺
?????Quantity of the impeller unit: ?Two sets.
3.6 ?提升機提升量：≥90?t/h
?????Quantity of the bucket elevator: ≥90?t/h
3.7 ?提升速度：＞1.2m/s
?????Lift speed: ＞1.2m/s
3.8 ?提升機功率?：≥7.5?kW
????Power of the bucket elevator: ≥7.5?kW
3.9 ?分離器分離量?：≥90?t/h
????Seperating quantity of bucket elevator: ≥90?t/h
3.10 ?分離區(qū)風速：4,000-5,000mm/s
????Air speed in the seperative zone: 4,000-5,000mm/s
3.11 ?輸送器輸送量：≥90t/h
????Conveying quantity of the conveyor: ?≥90t/h
3.12 ?輸送器功率?：4kW
????Power of the conveyor：4?kW
3.13 小除塵通風量?：5000 m3/h
?????Small dust collect required?ventilation capacity?: 5000 m3/h
?????風機功率：5.5kW
Power of the fan：5.5kW
?????彈丸風力回收風機風量: 120000 m3/h
?????Air blower?capacity?for abrasive recovery: 120000 m3/h
?????風機功率：90kW
Power of the fan：90kW
3.14?拋頭輸送系統(tǒng) ?Blast wheel transport system
????輸送速度（在直徑1米的鋼管尺寸）：0～2m/min(變頻調(diào)速)
?Transport speed at steel pipe diameter is 1 meter ?:?0～2m/min(Frequency conversion)
減速機功率：3kW????Reducer power : 3kW
3.15?鋼管移動小車 steel conveying flatcar
輸送速度：0～20m/min(變頻調(diào)速)
Transport speed :?0～20m/min(Frequency conversion)
減速機功率：2.2kW?*3 ??Reducer power : 2.2kW*3
3.16 彈丸皮帶機供丸系統(tǒng)
?????Belt conveyor?abrasive supply?system
?????供丸量：200－900kg/min ???abrasive supply capacity: 200－900kg/min
?減速機功率：2.2kW????Reducer power : 2.2kW
3.17鋼管自轉(zhuǎn)系統(tǒng)
?????Pipe rotation system
?自轉(zhuǎn)速度：0～20m/min(變頻調(diào)速)
Rotation speed :?0～5m/min(Frequency conversion)
自轉(zhuǎn)功率：4kW*3 ??rotation power: 4kW*3
耐高溫聚氨酯膠輪
High temperature resistant pu tire
3.18 移動密封系統(tǒng) ???moveable sealing room
?????移動速度：20m/min?????Move speed :20m/min?
?????減速機功率：2.2kW????Reducer power : 2.2kW
3.19 鋼管液壓裝卸料系統(tǒng)
?????Steel pipe hydraulic loading and unloading system
3.20?總功率：約350kW ?
????Total power: approx : 350kW
3.21?拋丸用鋼丸直徑：?0.8-1.5mm
????Diameter of the shot ball : 0.8-1.5mm
3.22?輸送臺車**承載能力：≥20000kg
????Conveying car Largest loading capability: ?≥20000kg
3.23?清理后表面質(zhì)量：達到GB8923-88, ?A-B , Sa2.5級
????Surface quality cleaned: get GB8923-88, ?A-B , Sa2.5 level.
3.24壓縮空氣總耗氣量：約60m3/h
????Air consumption in compressed air: about 60m3/h
3.25壓縮空氣壓力5-6kg/cm2
??????Pressure of compressed air: 5-6kg/cm2
3.26 設(shè)備可以手動操作和自動操作自由切換
????Can manual and automatic operation and free switch?each other
四、設(shè)備結(jié)構(gòu)和部件說明
Equipment Composition and Various Parts Explanation
1.?主要構(gòu)成
該設(shè)備主要由前后可移動副室、固定密封室，內(nèi)壁液壓可移動拋丸器、鋼管自傳裝置、皮帶機式彈丸輸送機構(gòu)、底部皮帶輸送器、提升機、維修平臺、分離器、除塵系統(tǒng)、內(nèi)壁拋丸器行走機構(gòu)、鋼管上卸料機構(gòu)、液壓系統(tǒng)及電控系統(tǒng)等。
??1.?Main composition
???The equipment?are constituted of : moveable sealing room ,fixed sealing room, steel pipe moveable Hydraulic shot blast wheel ,steel pipe rotation system, belt converying abrasive supply system,steel pipe transport flatcar,abrasive recycling belt at the bottom .elevator ,maintenance platform ,separate ,dust collect system ,shot blast wheel transport system,hydraulic loading and unloading system ,hydraulic system and electrical?system.
2.工作原理
首先將鋼管通過液壓上料機構(gòu)裝載到輸送小車上，3臺輸送小車帶動鋼管同時向固定密封室移動，移動到預(yù)定位置后，臺車停止.移動密封室和移動液壓拋丸器一起向鋼管的另一端移動，將鋼管端部完全密封后到檢測位置后，移動密封室停止，這時鋼管處于封閉狀態(tài)，內(nèi)壁液壓拋丸器在臺車帶動下，到達固定密封室端，然后依次開動鋼管自轉(zhuǎn)機構(gòu)，內(nèi)拋頭，彈丸輸送機構(gòu)，除塵系統(tǒng)，和內(nèi)拋頭移動平車，這樣鋼管旋轉(zhuǎn)內(nèi)拋頭行走并向鋼管的側(cè)壁拋射彈丸，完全通過鋼管后就把鋼管的內(nèi)壁清理好。????????????????
2、拋丸清理機
鋼結(jié)構(gòu)拋丸清理機
金屬履帶式拋丸清理機
輥道通過式拋丸清理機
懸鏈式拋丸清理機
吊鉤式拋丸清理機
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鋼板預(yù)熱輥道通過式拋丸清理機
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鋼結(jié)構(gòu)型材輥道通過式拋丸清理機
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掛車清理前圖；
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掛車清理后效果圖；
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