Manufacturing Process of Filter Element Framework
1. Equipment required:
Electric welding machine
2. Types and uses of skeleton
The types of skeletons are divided into: inner skeletons, outer skeletons and middle skeletons; According to the material, there are: stainless steel skeleton, cold plate skeleton, aluminum plate skeleton and plastic skeleton; According to the hole, there are: round hole, square hole, diamond hole and rectangular hole.
Purpose of framework: it is to support and protect the corrugations to avoid bumping or crushing or damaging the corrugations under the action of external forces. It should not only be beautiful, but also meet the requirements of strength.
3. Production process of skeleton
Skeleton blanking: when picking, discharging and blanking according to the requirements of the drawing, the plate shall be cut into a square plate with vertical edges, not into a diamond, so as to avoid the deviation of the weld after the circle and the influence of the axis on the appearance. During the blanking of the first piece, it is necessary to check whether the blanking size meets the requirements of the drawing. Only when it meets the requirements of the drawing can the batch blanking be carried out. When the batch is large, the size shall be measured after every 10 pieces, to prevent the positioning plate from moving, all dimensions and quantities shall be inspected after blanking. If it is lap welding, the lap line shall be drawn.
Skeleton circle: determine the direction and front and back sides of the circle according to the drawing. During the circle, the plate shall be vertically placed in the circle machine. The end face of the circle shall not be misaligned too much to avoid difficult alignment of the ends during welding.
Lap welding: first adjust the current of the welding machine (the current of the welding machine should be moderate to avoid burning through the framework with too large current or welding is not firm with too small current) and test the welding condition with waste materials. The finished product welding can be carried out only when the requirements are met. During the welding of finished products, the end faces shall be aligned, and one end shall be welded according to the overlapping edge line, and then the other end shall be welded in the same way, and then the middle shall be welded, Zui and then evenly according to the requirements of the drawing. After welding, it shall enter the next cycle again. The welding part shall not be burnt out, the burr at the welding point shall not be too large, and the welding shall be firm.
Argon arc welding: first adjust the current and test the welding condition with waste materials. When the requirements are met, the finished product welding can be carried out. When welding the finished product, clamp the skeleton on the bench vice, align the end and end face, electric weld a few points at the flat place, then knock down the weld, and then weld according to the welding distance required by the drawing. After welding, enter the next cycle again. The welding part shall not be burnt out and the welding spot shall be penetrated, and the welding shall be firm.
Rounding: put the semi-finished product into a suitable cylinder according to the dimensions required in the drawing, knock it round and trial assemble it with the end cover.
Grinding: grind both ends and welding joints of the frame. The verticality of the trimmed frame shall be 500mm, no deviation of 2mm, no burr and hand scraping, and the surface shall be smooth and flat. When the grinding meets the requirements of the drawing, it shall be placed in the semi-finished product area.
Matters needing attention:
The thickness of product skeleton plate, punching hole diameter and hole spacing of the same batch shall be consistent.
The surface of the framework shall be flat and smooth without burrs, flash, weld beading and uniform spacing between holes, without staggered holes, leakage holes and serious uneven row spacing.
The rough surface of the framework faces the filter layer and the smooth surface faces outward, so as to achieve the purpose of beautiful appearance of the product. (however, the rough surface of the skeleton shall be free of burrs)
The surface treatment of the skeleton shall be uniform in color, complete, dense and smooth on the surface, without scratches, bumps and other abnormalities.
Manufacturing process of end cover:
1. Equipment required:
Lathe, milling machine, punch, electric welding machine, etc
2. Types and uses of end caps
The types of end caps are divided into: thin plate special-shaped cover, plane cover, groove cover with rubber ring and machined bar end cap according to shape; steel end cap, rotary stamping iron end cap, aluminum end cap and stainless steel end cap according to material; adhesive end cap and welding end cap according to connection method.
Purpose of end cover: it is used to connect equipment and fix and seal filter layer. In order to avoid filter medium bypass connection, it not only requires smoothness and beauty, but also requires the degree of connection size to ensure the reliability of connection.
3. Production process of end cap
Cold rolled sheet end cap:
（1） Rounding of thin plate end cover (commonly known as end cover): stack the lower square end cover materials on the lathe according to the requirements of the drawing, install the front positioning tooling on the three claws of the lathe, and the rear positioning tooling on the tailstock of the lathe, shake * install the end cover materials, adjust and tighten them, so as not to loosen the end cover materials, and clamp the thin plate cutting knife on the lathe tool holder for cutting, After slicing to meet the requirements, remove the sheet and put it into the specified area.
（2） Spinning of end cover: clamp the turned turntable on the window chuck, put the cut end cover material (disc) in the middle, and use a top plate close to the size of the turntable to top the end cover material at the other end, and then clamp a spinner on the tool holder for spinning. There shall be no obvious expansion at the flanging of the end cover after spinning, and the spinning size shall meet the requirements of the drawing.
（3） Cut the inner hole of the end cover material: put the end cover material on the opening fixture (Tooling) and clamp it on the chuck of the lathe (the opening fixture can not be used for single piece), cut it with an iron sheet cutting knife, and determine the required size according to the process from small to large, When cutting a hole without an opening fixture, pay attention to the deformation of the end cover and the flying out of the loose iron disc from the chuck.
（4） Stamping of end cover: before stamping the end cover, the burr shall be polished, then the end cover to be punched shall be put into the die, and then the rubber plate shall be pressed. The rubber plate shall be higher than the die for stamping. After stamping, take out the end cover from the die to observe whether there is wrinkling or fracture. If there is wrinkling, add the rubber plate, and if the fracture can reduce the rubber plate, If the requirements of the end cap cannot be met after one stamping, the method of adding rubber plate or adding gasket on the punch can be used for multiple stamping until the requirements of the drawing are met.
（5） Welding of end cover: adjust the current of electric welding machine until it meets the requirements. For example: welding of iron sheet end cover with rubber ring groove: (1) first put the mandrel (die) into the inner and outer cover to be welded, and then put the end cover flat between two welding electrode arms for welding. (2) Welding requirements: the welding position of the end cover shall be firmly welded, and there shall be no welding damage or excessive welding burr. If there is a small burr during welding, it shall be polished with a polishing grinder and placed in the area to be inspected.
2. End cover of machine feeding bar:
（1） Cutting and boring of bar material: the bar material shall be cut off on the round car, and the cutter shall be as thin as possible to reduce the waste of bar material. Boring: the small hole end cover shall be drilled on the lathe with a drill, and then bored with a boring cutter; The large hole end cover shall be bored with a boring cutter (so that the mandrel in the hole can be completely left for reuse next time) and then cut off to reduce the cutting amount.
（2） Processing requirements of bar end cover: it shall be processed according to the requirements of the drawing, with good surface finish and size, and there shall be no sharp angle, bruise, burr and other phenomena.
Matters needing attention:
The thickness and material of the end cover plate of the same batch of products shall be consistent.
When assembling and welding the end cover, avoid excessive or too small current, which will affect the appearance quality of the product.
The end cover shall be free of burrs, flash, weld beading and other undesirable phenomena.
The surface treatment of the end cover shall be complete, dense, uniform in color, and free from scratches, bumps and other abnormalities.
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