CN115178975A - Production process of energy storage box - Google Patents
Production process of energy storage box Download PDFInfo
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- CN115178975A CN115178975A CN202210864518.4A CN202210864518A CN115178975A CN 115178975 A CN115178975 A CN 115178975A CN 202210864518 A CN202210864518 A CN 202210864518A CN 115178975 A CN115178975 A CN 115178975A
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- 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
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Abstract
The invention relates to the technical field of energy storage box production processes, and discloses a production process of an energy storage box, which comprises the following steps of S1: materials such as plates/sectional materials, sheet metal parts, nut and bolt connecting pieces, adhesive tapes and the like are purchased outside the department, and can be put in storage after quality special inspection is qualified, and are put in storage in batch production after quality inspection of first parts of the self-made parts is qualified; s2, material pretreatment: carrying out pretreatment procedures on the plates and the sectional materials, including oil removal, sanding, soot blowing and primer pre-spraying; s3, component assembly: welding and finishing the component; s4, final assembly welding: sequentially hoisting the components, and performing box body assembly welding; s5, processing again: carrying out quality inspection, sanding, powder spraying, sealing and other processing on the whole box; s6, installing: filling side plates, correcting and finishing; and S7, finishing assembly, packaging and delivering goods. The careful treatment is carried out for a plurality of times in microcosmic and macroscopic view, the rigor of the process and the quality of the box body are improved, the quality of the box body of the energy storage box is improved, the appearance defects of the box body are reduced, and the box body is more attractive and durable.
Description
Technical Field
The invention relates to the technical field of energy storage box production processes, in particular to a production process of an energy storage box.
Background
The energy storage box is an important embodiment of a new technology, a new material and new equipment applied to an intelligent substation, and comprises an energy storage box body, a secondary equipment screen cabinet (or a rack), cabin body auxiliary facilities and the like, and is transported to a project site as a whole after a series of complex processes such as manufacturing, assembling, wiring, debugging and the like are carried out in a factory, and the energy storage box is located on an installation basis. At present, the conventional electrical system layout, civil engineering design and construction mode of a transformer substation are changed by a full energy storage box assembly type transformer substation, and the transformer substation is built through two major stages of factory production prefabrication and field installation. The standard design, the modular combination, the industrial production and the intensive construction of the transformer substation enable the construction of the transformer substation to be high in content, less in environmental pollution and capable of finely constructing roads.
The energy storage box and the secondary equipment inside the energy storage box realize that the whole set of secondary equipment is integrated by a manufacturer, so that the factory processing is realized, the secondary wiring on site is reduced, the design, construction, debugging and workload are reduced, the overhaul and maintenance work is simplified, the construction period is shortened, and the power grid construction is effectively supported. The cabin body is generally not provided with a window, and ventilation is realized by adopting a fan and an air conditioner. Heating and ventilation facilities such as an air conditioner, an electric heater, a fan and the like, and a window for facilitating lighting and ventilation in the air conditioner, a master control room and a duty room should be arranged.
But some manufacturers only carry out one-time finishing in the production process of the energy storage box at the present stage, and the single oil removal, sanding and soot blowing result in obvious and unattractive welding seams of the welded energy storage box, poor water tightness and poor quality; therefore, the existing requirements are not met, and a production process of the energy storage box is provided for the requirement.
Disclosure of Invention
The invention provides a production process of an energy storage box, which has the beneficial effects of solving the problems that some manufacturers in the prior art only carry out one-time finishing in the production process of the energy storage box, and the welded energy storage box has obvious and unattractive welding seams, poor water tightness and poor quality caused by single oil removal, sanding and soot blowing.
The invention provides the following technical scheme: a production process of an energy storage box comprises the following steps:
s1, material preparation: materials such as plates/sectional materials, sheet metal parts, nut and bolt connecting pieces, adhesive tapes and the like are purchased outside the department, and can be put in storage after quality special inspection is qualified, and are put in storage in batch production after quality inspection of first parts of the self-made parts is qualified;
s2, material pretreatment: carrying out pretreatment procedures on the plates and the sectional materials, wherein the pretreatment procedures comprise oil removal, sanding, soot blowing and primer pre-spraying;
s3, assembling components: respectively welding and finishing components of accessories such as a bottom frame part, front and rear end frame parts, a top plate part, left and right side frame parts, an in-box partition and the like;
s4, final assembly welding: sequentially hoisting the components, and performing box body assembly welding;
s5, processing again: carrying out quality inspection, sanding, powder spraying, sealing and other processing on the whole box;
s6, installing: filling side plates, correcting and finishing;
s7, finished assembly, packaging and delivery: checking and wire returning processing are carried out on all nuts and studs, grease is used for blocking holes for welding blind hole nut holes, accessories are assembled, pasting of marks is completed according to a mark drawing, integral glue sealing is carried out, and packaged goods for delivery are placed in a box and are properly fixed according to a list.
As an alternative to the production process of an energy storage tank according to the invention, wherein: and S3, component assembling and welding of the bottom frame component comprises the following specific steps:
s311, checking the specification of each component, distinguishing the components according to the difference of the thicknesses of the left bottom side beam and the right bottom side beam, checking the length of the incoming material of the bottom side beam, and checking the position size of each blind hole nut hole according to a part drawing;
s312, installing and welding an m16 blind nut, flatly installing the surface of the blind nut and the surface of a base material, screwing a bolt before welding to prevent the bolt from splashing and damaging screw threads, smoothly polishing a convex welding line, and correcting welding side bending on a straightening machine;
s313, marking a bottom beam channel steel positioning line on a bottom side beam, spot-welding a bottom side beam backer by a bullet line on a tooling platform, hanging the bottom side beam into the tooling platform to be closely attached to each backer to ensure straightness, sequentially placing the bottom side beam into the bottom beam channel steel, and spot-welding and fixing;
s314, assembling a bottom support C-shaped part, and welding m8 nuts on the grid mounting beam to complete the welding of the bottom cross beam channel steel, the bottom support C-shaped part, the grid mounting beam and the bottom side beam;
s315, placing the steel floor in sequence, flatly installing the steel floor and a bottom beam channel, densely spot-welding and fixing the steel floor and the bottom beam channel at intervals of 50mm, hanging the bottom frame to raise the frame, firmly attaching the steel floor and a bottom support C-shaped piece, and spot-welding and fixing.
As an alternative to the production process of an energy storage tank of the invention, wherein: and S3, carrying out component assembly welding on the front end frame and the rear end frame, and comprising the following specific steps:
s321, assembling the corner columns, the upper cross beam and the lower cross beam, and reducing welding deformation by adopting vertical welding;
s322, assembling a frame, flattening an upper cross beam and an upper opening of a top corner piece, placing a front wall plate, assembling upright post square tubes at the inner end of a welding box, assembling support angle steel, and marking a positioning line by using a template to ensure the precision of the support angle steel;
s323, marking and punching a front wall plate, paying attention to the size of the punched hole, and installing and welding each wire box;
s324, welding stainless steel grounding, and pasting paper for protection during welding.
As an alternative to the production process of an energy storage tank of the invention, wherein: and S3, welding the components in the left and right side frame parts, which comprises the following specific steps:
s331, checking hole forming precision and concentricity of incoming materials of a side upright column and a top side beam of the left side frame;
s332, welding a stainless steel M10 blind hole welding nut on the top side beam of the left side frame, paying attention to thread protection during welding, and welding a carbon steel M6 blind hole welding nut on the side upright post;
s333, placing a top beam on the left side frame tooling platform, straightening the top beam to be tightly attached to the backer by using a screw rod and turnbuckles, sequentially placing each side stand column, and strengthening the lower opening of each stand column by using process support spot welding;
s334, welding a door lintel beam on the left side frame, wherein the left side frame is flush with the requirement of the upright column, and welding seams at two ends are polished to be flat so that no depression or protrusion is obtained;
s335. Welding a right side plate jointed plate, wherein the permeability of the reverse side is more than or equal to 95%, correcting the camber at a welding joint by using an air cylinder after welding to be less than or equal to 2mm, welding a stainless steel M10 blind hole welding nut on the top beam square tube, assembling the side plate and the top beam according to 6mm, ensuring that the side plate is 90 degrees vertical to the top beam, and completing the upper corrugated welding.
As an alternative to the production process of an energy storage tank of the invention, wherein: s3, in the process of welding and assembling accessories such as partitions in the box, a top cross beam and partition wall stand columns are placed on a tooling platform, all components are tightly attached to the backer, accessories such as fire-fighting pipeline fixing pieces and threading welding pieces are welded at the notches of the partition wall plates, the welding seams of all angle iron supports and the upper openings of the partition wall stand columns are prevented from being too thick, and the welding feet are controlled to be about 3 mm.
As an alternative to the production process of an energy storage tank according to the invention, wherein: and S4, after the assembly welding of all the parts is completed, completing the welding of places such as pit, ripple welding, in-box welding, vertical welding, top welding and the like, assembling and welding small parts such as an exhaust mechanism assembly, a top threading box assembly, a lifting lug, a side inclined support, a top inclined support and the like, assembling and welding a keel, and assembling and welding threshold beams at all the door frames.
As an alternative to the production process of an energy storage tank according to the invention, wherein: the left side frame is 8 door frame structures, is equipped with 8 guest and supplies the door plant, and the door plant assembly back carries out the watertight test and does not have the seepage.
As an alternative to the production process of an energy storage tank of the invention, wherein: and S5, sanding the welding line of the whole box, checking the missing part of the dead angle, and performing manual polishing treatment on the missing part, and finally treating the welding problems such as welding defects, splashing, light leakage, hard damage and the like.
As an alternative to the production process of an energy storage tank according to the invention, wherein: and in S5, powder spraying is carried out twice, after spraying for the first time, watertight tests are carried out on the top and the side of the box body, the top is submerged for 2 hours by using a tool, spraying is carried out on the side by using a water gun, whether leak points exist in the box body is checked, the leak points are subjected to repair welding, then, internal installation is carried out in S6, and powder spraying is carried out for the second time after the internal installation is finished.
As an alternative to the production process of an energy storage tank according to the invention, wherein: and S6, decorating the right side, the top and the like of the box body in a mode of filling rock wool and covering a galvanized plate, wherein the rock wool is tightly filled without gaps, and broken blocks cannot be used for filling.
The invention has the following beneficial effects:
1. the production process of the energy storage box is divided into parts, each part is used after being subjected to quality detection, and the parts are divided into parts by adopting the mode of assembling each component and assembling the whole box, so that the detailed treatment is carried out on the micro and macro for many times, and the rigidness of the process and the quality of the box body are improved; the method comprises the following steps of stamping and preprocessing a self-made part before the components of each part are assembled and welded, so that each component meets the requirements of a drawing, and adopting dustproof and moistureproof measures to ensure the quality of the component, so that each part meets the requirements after being assembled and welded, and the probability of problems during the final assembly and welding is reduced; handle once more after the assembly welds for the welding seam is polished, and roof, curb plate piece are automatic to be welded and are dabbed lightly and prevent to warp, omit to the dead angle position and handle, make welding defect, splash, welding problems such as light leak, hard damage obtain solving, improve the quality of energy storage box, reduce box appearance defects, make the box more pleasing to the eye, durable.
2. According to the production process of the energy storage box, the left side frame, the right side of the box body, the top and the like are subjected to watertight tests respectively, so that the watertightness of the box body is detected for multiple times, the quality of the box body is improved, and the safety of the energy storage box in power distribution use is kept; and the two sides are matched with watertight tests, powder spraying is divided into two times, and the box body after the watertight tests is subjected to defect checking and leakage repairing, so that the quality of the box body is further improved.
3. When the energy storage box is internally installed, rock wool fragments are not used, the whole rock wool is tightly filled without gaps, the heat preservation and heat insulation capacity and the fireproof capacity of the right side, the top and other parts of the box body are enhanced, and the level of the energy storage box production process and the quality of the box body of the energy storage box are further improved.
Drawings
FIG. 1 is a schematic block diagram of the process flow of the present invention.
FIG. 2 is a schematic process flow diagram of the present invention.
Fig. 3 is a perspective view of the finished energy storage tank of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
The embodiment is intended to promote and solve the problems that some manufacturers only perform one finishing in the production process of the energy storage tank at the present stage, and the weld joints of the energy storage tank after welding are obvious and unattractive due to single oil removal, sanding and soot blowing, the size is not strict, the water tightness is poor, and the quality is poor, and please refer to fig. 1 to 3, the production process of the energy storage tank comprises the following specific steps:
s1, material preparation: the method comprises the following steps that materials such as plates/profiles, sheet metal parts, nut and bolt connecting pieces, adhesive tapes and the like are purchased outside in an outsourcing mode, and can be warehoused after quality special inspection is qualified, and the materials are produced in batches and warehoused after quality inspection of first parts of the self-made parts is qualified;
s2, material pretreatment: carrying out pretreatment procedures on the plates and the sectional materials, including oil removal, sanding, soot blowing and primer pre-spraying;
s3, component assembly: respectively welding and finishing components of accessories such as a bottom frame part, front and rear end frame parts, a top plate part, left and right side frame parts, an in-box partition and the like;
s4, final assembly welding: sequentially hoisting the components, and welding the box body;
s5, processing again: carrying out quality inspection, sanding, powder spraying, sealing and other processing on the whole box;
s6, installing: filling side plates, correcting and finishing;
s7, finished assembly, packaging and delivery: and (3) checking and returning all nuts and studs, welding blind holes and nut holes, plugging the holes by using grease, assembling accessories, pasting marks according to a mark diagram, performing integral glue sealing, and putting packaged goods for delivery into a box and properly fixing according to a list.
When the self-made piece is produced, the quality department special inspection is reported after the self-inspection of the first piece production of each procedure is finished, the first piece special inspection is reworked and repaired if abnormal, or the solution is output by the review of technical, technological and quality related personnel until the first piece of the product is qualified, and then the mass production is carried out. And welding abrasion, thin plate hard damage, paint scratch and foot print pollution are controlled in the production and processing process, and randomness is avoided.
In the process of material pretreatment, plates and profiles need to be subjected to pretreatment procedures (oil removal, sanding, soot blowing and primer spraying), and the general requirements are as follows: the cleanliness grade of the sanded material is Sa2.5;3.1.3 surface dust rating not higher than 3;3.1.4 the thickness of the primer dry film is 5-10 mu m;3.1.5 the surface roughness is Rz25 to 50 μm. When the steel plate is stamped, attention should be paid to not pollute the material subjected to surface treatment again, proper measures should be taken for dust prevention and moisture prevention during stacking, the dryness of the stacking environment can be ensured by using dry materials, and dust-proof cloth is used for covering the material.
When the components of the bottom frame part are installed and welded, the left bottom side beam and the right bottom side beam are different in specification, the left bottom side beam is 8.0mm thick, the right bottom side beam is 4.0mm thick, the incoming length of the bottom side beam is inspected to be 9446mm, and the position size of each blind hole nut hole is inspected according to a part drawing. And (3) installing and welding an m16 blind nut, flatly installing the surface of the blind nut and the surface of the base material, screwing a bolt before welding to prevent splashing and damage screw threads, polishing a convex welding line smoothly, and correcting the welding side curve on a straightening machine. And marking a bottom beam channel steel positioning line on the bottom side beam, wherein the step difference of the inner distance of 1066mm is 62mm, spot-welding a bottom beam backer by a bullet line on a tooling platform, hanging the bottom side beam into the tooling platform to be attached to each backer to ensure the straightness accuracy, controlling the inner width according to 1667+1mm, and sequentially putting the bottom beam channel steel into the tooling platform to be spot-welded and fixed. The bottom support C-shaped member was assembled with a step difference of 64mm from the bottom side beam. M8 nuts are welded on the grid mounting beam, and the step difference of the grid mounting beam and the bottom side beam is 95mm. Welding the bottom beam channel steel, the bottom support C-shaped part, the grid mounting beam and the bottom side beam is completed; sequentially placing the steel floor boards into the steel floor boards, flatly arranging the steel floor boards and the bottom beam channel steel, and densely spot-welding and fixing the steel floor boards and the bottom beam channel steel at intervals of 50 mm; the bottom frame is hung on the lifting frame, the steel floor is tightly attached to the bottom support C-shaped part and fixed by spot welding; installing and welding a fire-fighting pipeline fixing piece and a C-shaped support, wherein all the screw teeth are protected by using a paper adhesive tape; and installing and welding wire outlets, and positioning the welding wire outlets in the center of four edges of the hole of the steel floor.
When the components of the end frame parts are assembled and welded, the corner columns, the upper cross beam and the lower cross beam are all assembled parts, welding deformation is reduced by adopting vertical welding, the left corner columns at the front end and the rear end need to ensure that the straightness accuracy after welding of a door panel installation surface is within 2mm, the concentricity of the blind hole nuts is within 1mm, and alignment is carried out if the concentricity is out of tolerance. The frame is assembled according to 1700 (+ 3) mm 2471.5 (+ 3) mm, the upper beam is flush with the upper opening of the top corner piece, the lower beam and the lower opening of the bottom corner piece have step difference of 29mm, the step difference and the end surface of the corner piece are adjusted within 2mm of the diagonal line of the frame according to 4mm. The front wall plate is placed in the front wall plate, the left wall plate and the right wall plate are evenly divided according to 35mm, and the height difference between the front wall plate and the upper cross beam and the lower cross beam is 25 mm. And (3) arranging the inner end upright column square tube of the welding box and the upper cross beam to be flat according to 44mm, assembling supporting angle steel, and defining a positioning line by the supporting angle steel to ensure the precision. And marking a line on the front wall plate to open a hole, paying attention to the size of the hole, and installing and welding each wire box. When the stainless steel is welded, the paster is used for protection.
When the components of the left side frame are installed and welded, the incoming materials of the side upright posts and the top side beam are checked for hole opening precision and concentricity according to a part drawing. And a stainless steel M10 blind hole welding nut is welded on the top side beam, and the screw tooth protection is taken during welding. And a blind hole welding nut for welding carbon steel M6 is arranged on the side upright post. Putting the top beam on the tooling platform, straightening the top beam to be tightly attached to the backer by using a screw rod and a turnbuckle, sequentially putting the side stand columns, controlling the step difference between the stand columns and the top beam to be 58.5mm and the distance to be 1086+1mm, simultaneously checking the sizes of 1155.5mm +/-1 mm of door panel mounting holes, adjusting the diagonal error of each group of door frames to be within 2mm, and strengthening the lower openings of the stand columns by using process support spot welding. The door lintel beam is welded and is parallel to the upright post, the welding seams at two ends are polished to be flat, and no depression or protrusion is formed. The sill beam and the lifting lug component are welded after the final welding.
When the components of the right side plate are installed and welded, the jointed plate is automatically welded to be attractive in shape, the reverse side permeability is larger than or equal to 95%, and the camber of the welded joint is corrected by an air cylinder after welding and is smaller than or equal to 2mm. And (3) welding stainless steel M10 blind hole welding nuts on the square tubes of the top beam (120mm, 60mm, 4.0 mm), assembling the side plates and the top beam according to 6mm, ensuring that the side plates are 90 degrees vertical to the top beam, and finishing the upper corrugation welding (leaving about 100mm at two ends without welding). And pre-spraying primer in the area shielded by the support columns on the inner surface of the side plate. The lifting lug is welded again during the general welding.
When the components of the top plate are installed and welded, the top plate is automatically welded to be attractive in appearance, and the primer is sprayed in advance in the area, shielded by the top cross beam, of the inner surface of the top plate. The top reinforcing square tube is spliced and welded in advance, and the upper surface is sprayed with primer in advance.
When the components of the partition plate are installed and welded, the top beam and the partition wall stand columns are placed on the tool platform, all the components are tightly attached to the backer, the distance between the two partition wall stand columns is 750.5mm, the lower opening spot welding process is supported and strengthened, and the welding of the joint is completed. And (4) welding the angle steel bracket, controlling the size of 805.5mm, paying attention to the eye position waist hole of the angle steel bracket at the outer side, and forming a round hole at the inner side. And checking the straightness of the partition upright column within 2mm by using a running rule. And a partition plate is assembled on the partition wall, and the partition plate is coplanar with the side surface of the upright post. The gap of the partition board is provided with accessories such as fire-fighting pipeline fixing parts, threading welding parts and the like, and the heat exchange support is welded during the general welding. The upper opening welding seams of all the angle iron brackets and the partition upright posts are prevented from being too thick, and the welding leg is controlled to be about 3 mm. The bottom of the tooling platform is leveled by using a level gauge, three partition walls form a group and are assembled into small assemblies, each partition wall is tightly attached to an backer during assembly, the size of 1086+1mm is guaranteed, the coplanarity of the front and back two surfaces and the diagonal error are within 2mm, and the small assembly is supported and reinforced by a spot welding process. The upper surface of the top beam is pre-coated with zinc powder primer. The internal partitions are 7 groups, the angle steel supports are welded on the partitions and used for installing battery shelves, and horizontal errors and coplanar errors of the angle steel supports on each group of opposite partitions are controlled.
After all the parts are assembled and welded, final assembly welding is carried out, firstly, the rear end frame is hung into the rear end frame, the bottom corner piece falls into the positioning block and is tightly attached to the backer, and the upper corner piece is adjusted to be vertical by spot welding turn buckle screws. Hanging into the right side beam and the bottom corner piece of the underframe according to 3mm, hanging the left side beam according to 30mm, hanging the lower opening according to 3mm, and fixing by spot welding. Then, the front end frame is hung, and the working procedures are the same as the above.
It should be noted that, during final assembly, the upper opening of the total length of the box body is controlled according to 9802mm, and the lower opening is controlled according to 9800 mm. The right side beam of the underframe is pre-arched according to 6mm, the left side beam is pre-arched according to 8mm, and three points of each pre-arch are arched upwards in an arc shape.
The left side plate is hoisted, the size from the rear end corner post to the first side upright post 1086+1mm is preferentially ensured during positioning, and then the upright posts are fixed by spot welding in sequence (note that the size is 1086mm for reexamination). And (5) hoisting the partition wall assembly, and checking and controlling the partition wall assembly to be coplanar with the side upright posts within 2mm by using a guiding rule. Assembling the supporting columns (precoated with zinc powder primer), and preferentially ensuring the coplanarity of the supporting columns with the partition wall upright column and the left side upright column during positioning. And (3) hanging the right side plate, uniformly dividing gaps between two ends of the top beam and the corner fittings, assembling the side surface and the corner fittings according to 3mm, assembling the top part according to 58mm, assembling the side plate and the bottom side beam according to 6mm, and sticking the side plate and the front and rear corner posts for spot welding. And adjusting the straightness of the top side beams on the two sides by using turnbuckles, assembling the top reinforcing square tube assembly, completing the welding seams of the partition wall top cross beam, the top reinforcing square tube assembly and the upper openings of the top side beams, and polishing the welding seams.
And (4) hoisting the top plate for spot welding and fixing, and then strengthening the left front and rear end corner posts and the underframe by spot welding process support. And completing pit, corrugated welding, in-box welding, vertical welding, top welding and the like. And small parts such as a welding exhaust mechanism component, a top threading box component, a lifting lug, a side face inclined support, a top inclined support and the like are installed and welded. And (5) installing and welding a keel (prefabricating and spraying primer in advance), and paying attention to the opening of the keel downwards. And (3) welding threshold beams at each door frame, wherein the two ends of each threshold beam are parallel and level to the side upright columns, the welding seams are polished to be flat and not sunk or protruded, and the straightness of the welded door frame beams is not more than 2mm by using a guiding ruler.
After final assembly welding, the size of the whole box is tested, four bottom corner pieces of the box body are adjusted horizontally, the nonstandard size of the box body is 9796 (+ 8) mm (+ 1700 (+ 3) mm (+ 2471 (+ 3) mm, the diagonal error of the bottom, the top and the side is less than or equal to 6mm, the end face is less than or equal to 3mm, and the single door frame is less than or equal to 2mm. The camber of the bottom side beam is 3-5 mm. The plumb bob is used for detecting the verticality error of the corner column and the side upright column to be less than or equal to 2mm. And checking that the levelness error of the angle steel bracket on each group of partition walls is less than or equal to 2mm. The partition wall uses battery layer frame examination dress, requires easily to put into the angle iron support downthehole. And (4) installing and welding two bin heat exchange supports, and controlling the coplanarity error of the two supports within 2mm.
And after the size is correct, the end face of the right lower corner piece of the front end frame is knocked with the steel seal, the factory code HD + the instruction number + the water flow number, and the steel seal needs to be clear.
The whole box is processed, sanding, trimming and polishing are carried out on the whole box, sanding is carried out on welding seams of the whole box (the top plate and the side plate are welded and lightly sanded automatically to prevent deformation), manual polishing processing is carried out on missing positions of inspection dead corners, and welding problems such as welding defects, splashing, light leakage, hard damage and the like are finally processed. And the compressed air is used for thoroughly blowing the steel grit and dust inside and outside the box. Grounding sticker protection is carried out on the rear angle steel support, the partition wall support and front and rear end stainless steel grounding (integral protection before sanding and front surface sticking after sanding), so that subsequent painting of conductive paint is facilitated, and finally zinc-rich primer is sprayed outside the whole box.
Spraying powder and drying. To the incasement decoration, positions such as box right side, top adopt outer covering galvanized sheet form decoration, and the galvanized sheet uses stainless steel self-plugging rivet fixed, and the clearance is equallyd divide all around during the sheet assembly, and every square roughness is less than or equal to 5mm when the sheet assembly the protection of paying attention to, avoid fish tail, hard injury deformation. A short drill bit is arranged in the inner part to avoid punching through the side plate and the top plate. After the installation, the inspection must be carried out. The gap of the built-in mask plate is strictly controlled within 3mm, so that the subsequent sealing molding is ensured to be attractive, and the upper screw threads of the partition plate are protected by using a paper adhesive tape.
And after the interior is finished, assembling and delivering the whole box, and checking and wire returning processing on all nuts and studs. The blind hole and nut holes are welded on the side upright columns and the top and bottom side beams and are plugged by grease. When the accessories are assembled, the bolts for fastening must be pasted with grease, excessive locking is avoided, and subsequent disassembly is facilitated. During all operations in the box, the paint at the bottom of the box is protected by using paper boards and plastic flooring. And finishing the posting of each sign according to the sign diagram. And (4) finishing the RAL9003 color glue sealing of the box body, and assembling the front end sign board and the rear end sign board only after the sealing glue is dried.
The packing delivery article are put into the case and are properly fixed according to the delivery list, the inside and outside inspection box is not collided and deformed, the box is clean and clean, the winding film is used for winding and wrapping the box body, the marks on the corner columns are protected by foam, and the waterproof protective covers are covered.
It should be noted that, when shipping and hoisting, a cloth hanging strip is needed, and a ceiling mode is adopted to avoid damaging the coating of the box body.
In this embodiment: the fine treatment is carried out for a plurality of times in the micro and macro aspects, so that the rigor of the process and the quality of the box body are improved; the method comprises the following steps of stamping and preprocessing self-made parts before the components of each part are assembled and welded, so that each component meets the requirements of a drawing, taking dustproof and moistureproof measures, ensuring the quality of the components, meeting the requirements after the components are assembled and welded, and reducing the probability of problems during assembly and welding; handle once more after the assembly welds for the welding seam is polished, and roof, curb plate piece are automatic to be welded and are dabbed lightly and prevent to warp, omit to the dead angle position and handle, make welding defect, splash, welding problems such as light leak, hard damage obtain solving, improve the quality of energy storage box, reduce box appearance defects, make the box more pleasing to the eye, durable.
Example 2
This embodiment is anticipated to promote to solve the poor water tightness of energy storage tank in the present stage, the not good problem of quality, and this embodiment is the improvement made on the basis of embodiment 1, and is specific, please refer to fig. 2, and the left side frame is 8 door frame structures, is equipped with 8 passenger and supplies the door plant, and the door plant is assembled the back, carries out the watertight test and does not have the seepage. The method comprises the following steps of spraying powder twice, performing top and side watertight tests on a box body after the powder is sprayed for the first time, submerging the top for 2 hours by using a tool, spraying by using a water gun on the side surface, checking whether a leakage point exists in the box body, performing repair welding on the leakage point, checking hard damage, grinding damage and deformation of the surface of the box body by using a highlight flashlight after the powder is sprayed, and finishing shaping and putty scraping treatment before flour spraying.
And (3) finishing the glue sealing (particularly three boxes at the top) of the decoration covering surface in the box, wherein the glue sealing is continuous, smooth and uniform in thickness, free from glue leakage and glue breaking, smooth in transition at the joint of the glue channel and free from protrusion, and then performing secondary powder spraying.
In this embodiment: the watertight test is respectively carried out on the left side frame and the right side, the top and other parts of the box body, so that the watertightness of the box body is detected for multiple times, the quality of the box body is improved, and the safety of the energy storage box in power distribution use is kept; and the powder spraying is divided into two times by matching with the watertight tests at two sides, and the box body after the watertight test is subjected to defect checking and leakage repairing, so that the quality of the box body is further improved.
Example 3
This embodiment is anticipated to promote to solve the not good problem of current stage energy storage box quality, and the improvement that this embodiment was made on embodiment 2's basis, and is concrete, when built-in, positions such as box right side, top adopt to fill rock wool, outer covering galvanized sheet form decoration, and rock wool fills the tight zero space, must not use the fragment to fill. And the flatness of the keel is checked before the rock wool is stuffed in, and the keel deformed by sanding is corrected.
In this embodiment: use rock wool to fill the curb plate for the curb plate has the thermal-insulated function of heat preservation, and does not use the rock wool fragment, and the monoblock rock wool is filled tightly and does not have the space, strengthens positions such as box right side, top heat preservation heat-proof capability and fire behavior, further improves the level of energy storage box production technology and carries the quality of energy storage box.
It should be noted that, in this document, relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the technical principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (10)
1. The production process of the energy storage box is characterized by comprising the following specific steps of:
s1, material preparation: materials such as plates/sectional materials, sheet metal parts, nut and bolt connecting pieces, adhesive tapes and the like are purchased outside the department, and can be put in storage after quality special inspection is qualified, and are put in storage in batch production after quality inspection of first parts of the self-made parts is qualified;
s2, material pretreatment: carrying out pretreatment procedures on the plates and the sectional materials, wherein the pretreatment procedures comprise oil removal, sanding, soot blowing and primer pre-spraying;
s3, component assembly: respectively welding and finishing components of accessories such as a bottom frame part, front and rear end frame parts, a top plate part, left and right side frame parts, an in-box partition and the like;
s4, final assembly welding: sequentially hoisting the components, and welding the box body;
s5, processing again: carrying out quality inspection, sanding, powder spraying, glue sealing and other processing on the whole box;
s6, installing: filling side plates, correcting and finishing;
s7, finished assembly, packaging and delivery: checking and wire returning processing are carried out on all nuts and studs, grease is used for blocking holes for welding blind hole nut holes, accessories are assembled, pasting of marks is completed according to a mark drawing, integral glue sealing is carried out, and packaged goods for delivery are placed in a box and are properly fixed according to a list.
2. The production process of the energy storage box according to claim 1, characterized in that: and in the S3, component assembling and welding are carried out on the bottom frame component, and the method comprises the following specific steps:
s311, checking the specification of each component, distinguishing the components according to the difference of the thicknesses of the left bottom side beam and the right bottom side beam, checking the length of the incoming material of the bottom side beam, and checking the position size of each blind hole nut hole according to a part drawing;
s312, installing and welding an m16 blind nut, flatly installing the surface of the blind nut and the surface of a base material, screwing a bolt before welding to prevent splashing and damage threads, smoothly polishing a convex welding line, and correcting a welding side bend on a straightening machine;
s313, marking a bottom beam channel steel positioning line on a bottom side beam, spot-welding a bottom side beam backer by a bullet line on a tooling platform, hanging the bottom side beam into the tooling platform to be closely attached to each backer to ensure straightness, sequentially placing the bottom side beam into the bottom beam channel steel, and spot-welding and fixing;
s314, assembling a bottom support C-shaped part, and welding m8 nuts on the grid mounting beam to complete the welding of the bottom cross beam channel steel, the bottom support C-shaped part, the grid mounting beam and the bottom side beam;
s315, placing the steel floor in sequence, flatly installing the steel floor and a bottom beam channel, densely spot-welding and fixing the steel floor and the bottom beam channel at intervals of 50mm, hanging the bottom frame to raise the frame, firmly attaching the steel floor and a bottom support C-shaped piece, and spot-welding and fixing.
3. The production process of the energy storage box according to claim 1, characterized in that: and in the S3, the front end frame and the rear end frame are subjected to component assembling and welding, and the method comprises the following specific steps:
s321, assembling the corner columns, the upper cross beam and the lower cross beam, and reducing welding deformation by adopting vertical welding;
s322, assembling a frame, flattening an upper cross beam and an upper opening of a top corner piece, placing a front wall plate, assembling upright post square tubes at the inner end of a welding box, assembling support angle steel, and marking a positioning line by using a template to ensure the precision of the support angle steel;
s323, marking and punching a front wall plate, paying attention to the size of the punched hole, and installing and welding each wire box;
s324, welding stainless steel grounding, and pasting paper for protection during welding.
4. The production process of an energy storage tank according to claim 1, characterized in that: and the assembly welding of the components in the left and right side frame parts in the S3 comprises the following specific steps:
s331, checking hole forming precision and concentricity of incoming materials of a side upright column and a top side beam of the left side frame;
s332, welding a stainless steel M10 blind hole welding nut on the top side beam of the left side frame, paying attention to thread protection during welding, and welding a carbon steel M6 blind hole welding nut on the side upright post;
s333, placing a top beam on the left side frame tooling platform, straightening the top beam to be tightly attached to a backer by using a screw rod and turnbuckles, sequentially placing each side stand column, and strengthening the lower opening of each stand column by using process support spot welding;
s334, welding a door lintel beam on the left side frame, wherein the left side frame is flush with the requirement of the upright column, and welding seams at two ends are polished to be flat so that no depression or protrusion is obtained;
s335, welding the right side plate by splicing, wherein the permeability of the reverse side is more than or equal to 95%, after welding, the cylinder is used for correcting the arch of the welding seam to be less than or equal to 2mm, a stainless steel M10 blind hole welding nut is welded on the square pipe of the top beam, the side plate and the top beam are assembled according to 6mm, the side plate is ensured to be 90 degrees vertical to the top beam, and then the upper corrugated welding is completed.
5. The production process of the energy storage box according to claim 1, characterized in that: s3, in the process of welding accessories such as partitions in the middle box, a top cross beam and partition wall stand columns are placed on a tool platform, all components are attached to the backer, the gap of each partition wall plate is welded with the accessories such as fire-fighting pipeline fixing pieces and threading welding pieces, the welding seams of the upper openings of all the angle steel supports and the partition wall stand columns are prevented from being too thick, and the welding feet are controlled to be about 3 mm.
6. The production process of an energy storage tank according to claim 1, characterized in that: and after the assembly welding of all the parts in the S4 is finished, the welding of places such as pit, ripple welding, in-box welding, vertical welding, top welding and the like is finished, small parts such as an exhaust mechanism assembly, a top threading box assembly, a lifting lug, a side face inclined support, a top inclined support and the like are assembled and welded, a keel is assembled and welded, and sill beams at all door frames are assembled and welded.
7. The production process of an energy storage tank according to claim 4, characterized in that: the left side frame is 8 door frame structures, is equipped with 8 guest and supplies the door plant, and the door plant assembly back carries out the watertight test and does not have the seepage.
8. The production process of the energy storage box according to claim 1, characterized in that: and in S5, sanding is performed on the welding seam of the whole box, manual polishing treatment is performed on the missing part of the inspection dead angle part, and final treatment is performed on welding problems such as welding defects, splashing, light leakage, hard damage and the like.
9. The production process of the energy storage box according to claim 1, characterized in that: in S5, twice powder spraying is carried out, after spraying for the first time, watertight tests of the top and the side of the box body are carried out, the top is submerged for 2 hours by using a tool, the side of the box body is sprayed by using a water gun, leakage points are detected in the box body, repair welding is carried out on the leakage points, then internal installation is carried out in S6, and powder spraying is carried out for the second time after the internal installation is finished.
10. The production process of an energy storage tank according to claim 1, characterized in that: in S6, the right side, the top and the like of the box body are decorated in the modes of filling rock wool and covering a galvanized sheet, the rock wool is filled tightly without gaps, and broken blocks cannot be used for filling.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN202210864518.4A CN115178975A (en) | 2022-07-21 | 2022-07-21 | Production process of energy storage box |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210864518.4A CN115178975A (en) | 2022-07-21 | 2022-07-21 | Production process of energy storage box |
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Cited By (1)
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| CN116944639B (en) * | 2023-09-20 | 2023-12-26 | 晋西铁路车辆有限责任公司 | Railway wagon plate column type end wall assembly welding process |
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Application publication date: 20221014 |