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CN-121988837-A - Quantitative adaptation and positioning method for spiral rib plates of heat exchange tube bundle of organosilicon fluidized bed

CN121988837ACN 121988837 ACN121988837 ACN 121988837ACN-121988837-A

Abstract

The invention relates to the technical field of manufacturing of organosilicon production equipment, in particular to a quantitative adaptation and positioning method for spiral rib plates of an organosilicon fluidized bed heat exchange tube bundle, aiming at the installation scene of the spiral rib plates of a vertical heat exchange tube bundle in an organosilicon fluidized bed reactor, the spiral rib plates are coaxially and uniformly positioned at the outer wall of the heat exchange tube bundle in a constant pitch without deformation by means of standard calibration, track scribing, tool positioning, multidimensional calibration, deformation prevention welding and post-welding correction full-flow closed loop control, and the order of magnitude of positioning accuracy is improved.

Inventors

  • XU MINGDA
  • NI QINGYI
  • CAI HAIJIAN
  • JI WEN
  • YIN HONGMEI

Assignees

  • 江苏科圣智能装备股份有限公司

Dates

Publication Date
20260508
Application Date
20260408

Claims (10)

  1. 1. The quantitative adaptation and positioning method for the spiral rib plates of the heat exchange tube bundle of the organosilicon fluidized bed is characterized by aiming at the installation scene of the spiral rib plates of the vertical heat exchange tube bundle in the organosilicon fluidized bed reactor, the spiral rib plates are coaxially installed at high precision, equal pitch and deformation-free positioning on the outer wall of the heat exchange tube bundle by reference calibration, track marking, tool positioning, multidimensional calibration, deformation-prevention welding and post-welding correction full-flow closed loop control, and specifically comprises the following steps: s1, preparing and calibrating design parameters in the early stage, finishing the incoming material inspection of a heat exchange tube bundle and a spiral rib plate, calibrating the design parameters of the spiral rib plate according to the process working condition of an organosilicon fluidized bed, and synchronously preparing a special combined positioning tool; S2, precisely scribing the datum of the heat exchange tube bundle and the spiral track, namely, completing continuous and equidistant scribing of the installation track of the spiral rib plate on the outer wall of the tube bundle by taking the matching surfaces of tube plates at two ends of the heat exchange tube bundle as axial datum and a tube body busbar as circumferential datum, so as to form a spiral installation datum; S3, clamping and standard calibration of a special combined positioning tool, horizontally clamping a heat exchange tube bundle on a numerical control rotary table, installing the special combined positioning tool, completing coaxiality, axial standard and circumferential standard calibration of the tool and the heat exchange tube bundle, and locking the positioning standard of the tool; S4, sectionally pre-positioning and primary fixing the spiral rib plates, sectionally attaching the spiral rib plates to the outer wall of the heat exchange tube bundle according to a spiral installation datum line, completing the pitch, the lift angle and the attaching gap limit of the single-section rib plates through a special combined positioning tool, completing the primary fixing of the single-section rib plates through spot welding, and synchronously completing the butt joint calibration of adjacent rib plate sections; S5, multi-dimensional precision real-time calibration and adjustment, namely carrying out five-dimensional precision detection on pitch precision, helix angle, coaxiality, circle run-out and fit clearance based on the initially fixed spiral rib plate, and carrying out micro adjustment on the out-of-tolerance part through a special combined positioning tool until all precision indexes meet the design tolerance requirement; s6, sectional symmetry deformation-preventing welding fixation, namely, full-welding fixation of the spiral rib plates and the heat exchange tube bundles is completed by adopting a sectional symmetry multi-layer multi-channel welding process, positioning constraint of the tube bundles and the rib plates is kept through a special combined positioning tool in the welding process, and welding deformation is controlled synchronously through infrared temperature measurement control; S7, performing post-welding precision re-inspection and micro-correction, removing the special combined positioning tool after the welding is cooled to room temperature, repeating the five-dimensional precision re-inspection, and performing the micro-correction on the out-of-tolerance part caused by welding deformation in a cold correction mode to ensure that all precision indexes are kept within a design tolerance range; And S8, final inspection and warehousing of the finished product, finishing final inspection of the appearance, the size and the form and position tolerance of the heat exchange tube bundle, and carrying out surface anti-corrosion treatment after the heat exchange tube bundle is qualified, so as to finish warehousing of the finished product.
  2. 2. The method of claim 1, wherein the heat exchange tube bundle in the step S1 is a seamless stainless steel tube bundle for an organosilicon fluidized bed, the outer diameter phi of the tube bundle is 38-57 mm, the wall thickness is 3-6 mm, the length of a single tube bundle is 3000-12000 mm, the spiral rib plate is stainless steel flat steel, the thickness is 3-8 mm, the width is 10-25 mm, the design pitch is 300-800 mm, the spiral angle is 10-25 degrees, the design parameter calibration is specifically that the pitch tolerance of locking spiral rib plates is +/-0.5 mm/m, the spiral angle tolerance is +/-0.3 DEG, the coaxiality tolerance of the rib plates and the tube bundle is less than or equal to 0.8mm, the jump tolerance of the outer edge circle of the rib plates is less than or equal to 1.2mm, and the fit clearance between the rib plates and the outer wall of the tube bundle is less than or equal to 0.2mm.
  3. 3. The method of claim 1, wherein the special combined positioning tool in the step S1 comprises a numerical control rotary supporting mechanism, an axial limit stop, an adjustable spiral guide die, a multi-dimension dial gauge detection assembly, a spot welding limit clamp and a welding deformation-preventing clamp, wherein the adjustable spiral guide die is provided with a guide groove matched with a spiral rib plate, and the pitch and the spiral angle of the guide groove can be adjusted steplessly through a screw rod mechanism to adapt to heat exchange tube bundles and the spiral rib plates with different specifications.
  4. 4. The method according to claim 1, wherein the spiral track precision scribing in step S2 is specifically performed as follows: s21, coaxially clamping two ends of a heat exchange tube bundle by using tips, and calibrating an axial 0-bit datum line and a total length datum of the tube bundle by taking tube plate sealing surfaces at two ends of the tube bundle as axial datum surfaces; s22, dividing a circumferential equally divided dividing circle on the outer wall of the tube bundle along the axial direction of the tube bundle at intervals of a designed pitch, and marking a circumferential starting point matched with a helix angle on each dividing circle; S23, continuously scribing a spiral installation datum line along the outer wall of the tube bundle by adopting a numerical control scribing instrument and taking an axial 0-bit datum line and a circumferential starting point as starting points, and simultaneously scribing rib plate width limit lines on two sides of the datum line to form a complete spiral installation track; s24, carrying out pitch and lead angle reinspection on the spiral track which is completed by drawing, wherein the accumulated error of the full-length pitch of the single tube bundle is less than or equal to 1mm, and the accumulated error of the lead angle is less than or equal to 0.5 degrees.
  5. 5. The method according to claim 1, wherein the specific operations of clamping the tooling and calibrating the reference in step S3 are as follows: S31, horizontally clamping a heat exchange tube bundle with a spiral track on a numerical control rotary table, fixing two ends through coaxial tips, and calibrating coaxiality between the axial direction of the tube bundle and the rotary center of the table to be less than or equal to 0.2mm; s32, installing axial limit stops at two ends of the workbench, attaching the axial limit stops to axial reference surfaces at two ends of the tube bundle, and locking axial displacement of the tube bundle; S33, installing an adjustable spiral guide die on a linear module of a workbench, adjusting the pitch and the spiral angle of the guide die to be consistent with design parameters, aligning a guide groove of the guide die with a spiral installation datum line of the outer wall of the tube bundle, and ensuring that the alignment error is less than or equal to 0.1mm; S34, installing a multi-dimensional dial indicator detection assembly on the workbench, and respectively calibrating radial circular runout of the tube bundle, axial runout of the outer edge of the rib plate and screw pitch displacement detection references to finish integral reference locking of the tool.
  6. 6. The method according to claim 1, wherein the specific operations of segment pre-positioning and initial fixing in step S4 are as follows: S41, sectionally blanking the spiral rib plates according to a single section length of 1000-1500 mm, leveling, straightening and removing burrs and oxide scales after blanking; S42, embedding a first section of spiral rib plate into a guide groove of an adjustable spiral guide die, enabling the inner side of the rib plate to be completely attached to a spiral installation datum line of the outer wall of the tube bundle, and fixing the positions of two ends and the middle section of the rib plate through a spot welding limit clamp; S43, performing interval spot welding on two sides of the rib plate by adopting argon arc welding, wherein the spot welding distance is 150 mm-200 mm, the spot welding length is 10 mm-15mm, and the spot welding penetration is not less than 1/3 of the thickness of the rib plate, so that the primary fixing of the single-section rib plate is completed; S44, driving the tube bundles to synchronously rotate by the numerical control rotary table, driving the adjustable spiral guide die to synchronously axially feed by the linear die set, repeating the operation to finish the pre-positioning and the primary fixing of the subsequent rib plate sections, adopting a butt joint groove at the butt joint position of the adjacent rib plate sections, enabling the butt joint gap to be less than or equal to 0.3mm, enabling the offset to be less than or equal to 0.2mm, and finishing the butt joint fixing by spot welding.
  7. 7. The method according to claim 1, wherein the five-dimensional accuracy calibration in step S5 is specifically: The pitch precision is that a laser range finder is adopted to detect the single-section pitch and the total length accumulated pitch, the single-section pitch error is less than or equal to +/-0.3 mm, and the total length accumulated error is less than or equal to 1mm; helix angle: an angle gauge is adopted to detect the axial included angle between the spiral rib plate and the tube bundle, the error is less than or equal to +/-0.2 degrees; Coaxiality, namely detecting coaxiality of the outer edge of the rib plate and the central axis of the tube bundle by adopting a dial indicator, wherein the error of the total length is less than or equal to 0.6mm; Circle jumping: the tube bundle rotates for one circle, the dial indicator detects radial circle runout of the outer edge of the rib plate, and the error of the full length is less than or equal to 1.0mm; And the bonding gap is that a clearance gauge is adopted to detect the bonding gap between the inner side of the rib plate and the outer wall of the tube bundle, the total section gap is less than or equal to 0.2mm, the local maximum gap is less than or equal to 0.3mm, and the accumulated length is not more than 5% of that of a single section rib plate.
  8. 8. The method according to claim 1, wherein the step S6 is performed by the following steps: s61, adopting pulsed argon arc welding, wherein the welding wire material is matched with the tube bundle and the rib plate material, the diameter phi of the welding wire is 1.6 mm-phi 2.4mm, the welding current is 80A-150A, and the welding voltage is 10V-18V; s62, adopting sectional symmetrical welding, dividing a spiral rib plate of a single tube bundle into 4-8 welding sections along the axial direction, and synchronously and symmetrically welding two ends by taking the midpoint of the tube bundle as a symmetrical center, wherein the welding length of each section is not more than 500mm; S63, adopting multilayer multi-pass welding, wherein a first layer is backing welding, so as to ensure the fusion quality of rib plates and tube bundles, a second layer and above are filling cover surface welding, the interlayer temperature is controlled to be 100-150 ℃, and real-time monitoring is carried out through an infrared thermometer; S64, in the welding process, the whole process of the adjustable spiral guide die and the welding deformation-preventing clamp is kept in positioning constraint, and when one welding section is completed, the form and position tolerance of the tube bundle and the rib plate is detected in real time through a dial indicator, and the welding sequence and the technological parameters are immediately adjusted when deformation trend occurs; And S65, after welding, carrying out appearance detection on the welded seam, wherein the residual height of the welded seam is 0.5 mm-1.5 mm, and the welded seam has no defects of undercut, unfused, air holes and cracks, and the butt welding seam of the adjacent rib plate sections is subjected to 100% penetration detection, so that the grade I is qualified.
  9. 9. The method of claim 1, wherein the post-welding rechecking and micro-correction in the step S7 are specifically implemented by removing all tool clamps after cooling to room temperature, repeating the five-dimensional precision rechecking in the step S5, performing micro-correction on the out-of-tolerance part caused by welding deformation by adopting a hydraulic cold correction tool, monitoring the shape and position change in real time by adopting a dial indicator in the correction process, and performing penetration detection on the corrected part until all precision indexes meet the design tolerance requirement, wherein the crack defect is avoided.
  10. 10. The method of claim 1, wherein the final inspection of the finished product in the step S8 is specifically that the final inspection of the dimensional tolerance and the form and position tolerance of the whole tube bundle is finished, the flatness and the straightness of the tube bundle of the matching surfaces of tube plates at two ends of the tube bundle are detected, the straightness of the whole tube bundle is less than or equal to 1.5mm/10m, the perpendicularity of the tube ends is less than or equal to 0.1mm, and after the final inspection is qualified, the tube bundle and the rib plates are subjected to pickling passivation surface treatment to finish the warehousing of the finished product.

Description

Quantitative adaptation and positioning method for spiral rib plates of heat exchange tube bundle of organosilicon fluidized bed Technical Field The invention relates to the technical field of manufacturing of organosilicon production equipment, in particular to a quantitative adaptation and positioning method for spiral rib plates of an organosilicon fluidized bed heat exchange tube bundle. Background The fluidized bed reactor for synthesizing methyl chlorosilane is core equipment for producing organic silicon, thousands of vertical heat exchange tube bundles are usually arranged in a single large fluidized bed reactor, the total length of the tube bundles can reach thousands of meters, the welding and installing workload of spiral rib plates is extremely high, and the requirements on positioning precision and welding quality are extremely high. At present, the traditional technology of manual scribing positioning, simple tool assistance and manual welding is generally adopted for installing a spiral rib plate of a heat exchange tube bundle in the industry, and the following technical defects and industry pain points which cannot be solved exist in actual production: The positioning accuracy is poor, and the consistency of finished products cannot be ensured. The installation efficiency is extremely low, and the large-scale production requirement cannot be adapted. The welding deformation control difficulty is high, and the qualification rate of finished products is low. The butt joint of the multi-section rib plates is misplaced, and flow field disorder and local abrasion are caused. The design requirement of the high-end fluidized bed cannot be met without a full-flow precision control system. Therefore, the quantitative adaptation and positioning method for the spiral rib plates of the heat exchange tube bundle of the organosilicon fluidized bed is provided. Disclosure of Invention In order to make up the defects of the prior art and solve the technical problems in the background art, the invention provides a quantitative adaptation and positioning method for a spiral rib plate of a heat exchange tube bundle of an organosilicon fluidized bed. The technical scheme adopted for solving the technical problems is that the quantitative adaptation and positioning method of the spiral rib plates of the heat exchange tube bundle of the organic silicon fluidized bed aims at the installation scene of the spiral rib plates of the vertical heat exchange tube bundle in the organic silicon fluidized bed reactor, and realizes the high-precision coaxial, equal-pitch and deformation-free positioning installation of the spiral rib plates on the outer wall of the heat exchange tube bundle by reference calibration, track scribing, tool positioning, multidimensional calibration, deformation-prevention welding and post-welding correction full-flow closed loop control, and the method specifically comprises the following steps: s1, preparing and calibrating design parameters in the early stage, finishing the incoming material inspection of a heat exchange tube bundle and a spiral rib plate, calibrating the design parameters of the spiral rib plate according to the process working condition of an organosilicon fluidized bed, and synchronously preparing a special combined positioning tool; S2, precisely scribing the datum of the heat exchange tube bundle and the spiral track, namely, completing continuous and equidistant scribing of the installation track of the spiral rib plate on the outer wall of the tube bundle by taking the matching surfaces of tube plates at two ends of the heat exchange tube bundle as axial datum and a tube body busbar as circumferential datum, so as to form a spiral installation datum; S3, clamping and standard calibration of a special combined positioning tool, horizontally clamping a heat exchange tube bundle on a numerical control rotary table, installing the special combined positioning tool, completing coaxiality, axial standard and circumferential standard calibration of the tool and the heat exchange tube bundle, and locking the positioning standard of the tool; S4, sectionally pre-positioning and primary fixing the spiral rib plates, sectionally attaching the spiral rib plates to the outer wall of the heat exchange tube bundle according to a spiral installation datum line, completing the pitch, the lift angle and the attaching gap limit of the single-section rib plates through a special combined positioning tool, completing the primary fixing of the single-section rib plates through spot welding, and synchronously completing the butt joint calibration of adjacent rib plate sections; S5, multi-dimensional precision real-time calibration and adjustment, namely carrying out five-dimensional precision detection on pitch precision, helix angle, coaxiality, circle run-out and fit clearance based on the initially fixed spiral rib plate, and carrying out micro adjustment on the out-of-tolerance part throu