LNG Vehicle Fuel Tank System

1.1 06Cr19Ni10LNG cylinder overall introduction: LNG welded insulated vehicle-mounted gas cylinder, made of stainless steel 06Cr19Ni10

1.2. Production process:

2.1 Italian DAVI four-roller rolling machine

The four-roller rolling machine is the easiest to operate and most productive rolling machine on the market today. This design has advantages that other types of rolling machines do not have:

The main advantages of the four-roller rolling machine compared to the general rolling machine:

1) The straight edge is shorter than any other rolling machine (good pre-bending)

2) The entire rolling process can be completed in one rolling, including double-sided pre-bending

3) It is usually 50%-80% more productive than the three-roller or any other type of rolling machine

4) The geometric design is perfect, and the workpiece after rolling has high precision and good roundness

5) The steel plate is fed horizontally (especially helpful for feeding long plates)

6) The steel plate is always clamped by the upper and lower rollers during the rolling process (no sliding)

2.2 Longitudinal seam spot welding machine

1) Prevent the weld from shrinking when welding one side of the cylinder first, and the other side will open without welding, which will affect the welding quality

2) The cylinder body is pushed into the longitudinal seam spot welding equipment by the turnover trolley, the infrared ray is aimed at the weld, the air belt drives the keys to press the cylinder body, the welding gun spot welds one point and then moves a certain distance to spot weld the next point, and the number of welding points is selected according to the distance requirements.

2.3 Longitudinal seam MIG automatic welding machine

The longitudinal seam automatic MIG welding equipment uses an open heightened type, which is mainly used for longitudinal seam butt welding of large stainless steel tanks. The plate thickness is 5-6mm, and the longitudinal seam is welded on both sides at one time. The welding speed reaches about 600mm/minute. The equipment has stable and reliable performance, good welding quality, beautiful welds, high welding efficiency and easy operation.

It adopts an open heightened welding equipment structure and is equipped with a track-moving hydraulic lifting platform. It adopts MIG melting electrode gas shielded welding and is equipped with Panasonic high-speed pulse MIG welding power supply. It adopts an open heightened longitudinal seam welding machine, the key finger pressing module presses the workpiece, the copper pad on the back of the weld is water-cooled, and the pneumatic locking shaft device ensures that the working parts have good rigidity and stable structure. The front of the weld is protected by argon gas. It adopts a visual laser centering device for easy operation. It is equipped with a track-moving hydraulic lifting platform and remote line control. The electrical control system of the equipment uses Mitsubishi PLC as the main control unit, and is equipped with a Pro-face color touch screen human-machine operation interface. Equipped with a safe and non-slip operating platform, welding power supply, chiller, argon cylinder, oxygen cylinder and fume purifier are placed on the operating platform to facilitate operation. The fume purifier is equipped to extract the fume generated during welding to achieve environmentally friendly production.

2.4 Longitudinal seam P+T automatic welding machine

This equipment is based on the longitudinal seam plasma automatic welding equipment and adds a TIG welding head for weld base welding. Adding an oscillator to the TIG welding head can make the weld fuller.

This welding machine has the following advantages:

1) On 2.5-10mm plates, it can achieve no beveling, one-time penetration, single-sided welding and double-sided forming.

2) Use TIG to cover the surface to make the front weld beautiful and smooth, which is convenient for subsequent polishing.

2.5 Assembly and circumferential spot welding equipment

This equipment is a spot welding equipment for the upper and lower heads and the middle cylinder. It is independently developed and manufactured by our company and is suitable for the process requirements of simultaneous spot welding of the two ends. The whole machine has a compact structure, a reasonable horizontal layout, stable and reliable operation of each mechanism, flexible and convenient operation, and has a light curtain safety protection function, a programmed electrical automatic control system, and a human-machine interface operating system. It adopts MAG welding, which is firm, smooth and tidy after welding. The whole machine has 2 welding power supplies, arranged on the left and right sides, 1 on each side. Two MAG welding guns are evenly distributed on the left and right sides of the whole machine. The mold and welding gun of this machine are used for spot welding of steel cylinders with an outer diameter of 1008, with 2 welding points on each side.

The main shafts at the clamping ends on both sides are driven to rotate by servo motors with worm gear reducers. They have a self-locking function and the speed can be adjusted (the welding speed can be adjusted by changing the speed of the main shaft); the initial position of the workpiece rotation is programmed and automatically repeated; equipped with two sets of corresponding pre-positioning tools, with markings indicating the placement position (eccentric valve seat position), the welding gun mechanisms at both ends use slide modules to drive the welding gun to rise and fall, and the welding gun is also equipped with a fine adjuster, which fully meets the adjustment needs of the welding position; the left and right clamping mechanisms are driven by cylinders, and the initial clamping position can be manually adjusted according to the length and size of the cylinder; the tray mechanism in the middle has an electromagnet, which is convenient for placing the cylinder and taking the material after spot welding. The cylinder drive is used to automatically send the spot-welded cylinder to the discharge track. The running speed of each mechanism can be adjusted.

This equipment is operated by only one worker on the equipment, which not only reduces the user's equipment cost investment, saves energy, reduces losses, and reduces site occupancy; but also saves the number of workers and improves production efficiency.

2.6 Circumferential seam MIG automatic welding machine

This equipment is used for automatic welding of the circumferential seam at the joint of the upper and lower heads of steel cylinders. It uses weld vision + laser weld automatic tracking system to automatically find and track the weld seam, and automatically completes the circumferential seam welding without manual intervention; it uses a complete set of combined auxiliary machine systems of feeding conveyor line + magnetic suction manipulator device + three-station loading and unloading device + self-unloading roller + discharge conveyor line to automatically take out the steel cylinder to be welded from the feeding conveyor line and send it to the clamping position of the circumferential seam host to complete the loading, and at the same time, the welded steel cylinder is unloaded from the circumferential seam host and sent to the discharge conveyor line; the production line is fully automated and unmanned, and can be managed by one person. Each device is equipped with a Panasonic high-speed welding power supply, a water-cooled welding gun, a circulating cooling water tank, and a set of weld vision + laser weld automatic tracking system. The mold is customized according to the specifications of the upper and lower covers. The electrical control system uses Mitsubishi PLC main control unit and Pro-face color touch screen operation interface.

The machine adopts a horizontal double-axis structure. The main shaft and tail shaft are coaxial. The cylinder drives forward and backward, and moves in opposite directions to clamp or loosen the workpiece. Before clamping the workpiece, the buffers of the clamping mechanisms at both ends first contact the workpiece to effectively prevent the workpiece from being deformed and damaged during the clamping process. The main shaft is driven by a servo motor, Mitsubishi variable frequency speed regulation, and the main shaft motor power is 0.75KW. The main shaft and tail shaft are each equipped with a welding mold. The position of the welding gun can be adjusted along the axis of the cylinder. The welding gun is equipped with a fine-tuning mechanism to accurately fine-tune the position of the welding gun. The head is equipped with a weld seam vision + laser weld seam automatic tracking system, an X\Y axis servo-driven welding gun, and a smoke exhaust pipe, which is convenient for users to centrally exhaust smoke. Equipped with a magnetic suction manipulator device, a three-station loading and unloading device, an inlet and outlet conveyor line, and a self-unloading roller.

2.7 Longitudinal seam real-time imaging flaw detector/circumferential seam real-time imaging flaw detector

Radiographic flaw detection uses X-rays to penetrate metal materials. Due to the different absorption and scattering effects of materials on rays, X-ray fluoroscopy and industrial television real-time imaging can quickly display internal defects of welds, thereby preventing and controlling quality problems. It is an important quality inspection equipment for product quality control of parts manufacturing companies.

Its advantages are:

1) Defects can be found in time;

2) Double penetration is achieved, with high efficiency;

3) Low cost of use;

2.8 Wrapping machine

This equipment is loaded and unloaded by a traveling crane. The motor drives the main shaft to rotate. First, the wrapping film is manually glued to the cylinder tube, which drives the rotation. The counter counts. When the designed wrapping thickness is reached, the rotation stops automatically. The excess part is manually cut and sealed with a special tape. The two sides of the cylinder are manually tied and sealed, and the excess part can be cut off.

The working principle of the wrapping machine is to put the cylinder in the center of the turntable: after the turntable motor rotates, it naturally drives the turntable to rotate, so that the object can be wrapped with the outer wrapping film.

2.9 Ultrasonic cleaning machine

Ultrasonic waves within a certain frequency range can clean workpieces when applied to liquid media. This cleaning technology has attracted widespread attention from all walks of life since its introduction. The use of ultrasonic cleaning machines has greatly improved work efficiency and cleaning effects. In the past, cleaning dead corners, blind holes, and hard-to-reach places where dirt and grime hide has always been a difficult thing. The development and application of new technologies have made this work easy.

2.10 Vacuum extraction equipment

There are three basic forms of heat transfer: heat conduction, heat radiation and heat convection. The equipment heats the air and circulates it in the inner cylinder, heating the inner cylinder and increasing the gas decomposition speed.

Vacuuming is to extract the medium in the cylinder shell and the inner cylinder, so as to achieve the purpose of reducing heat convection. The effect of heat preservation is affected by the vacuum degree. The better the vacuum effect, the better the heat preservation effect.

Rough vacuum part: rotary vane pump + screw pump unit pressure can reach 6x10-2 Pa

Fine vacuum part: molecular pump + rotary vane pump pressure can reach 6x10-5Pa

2.11 Helium leakage testing equipment

Use a rotary pump to extract the internal medium. When the medium reaches ﹤5Pa, start the helium detector, spray helium outside the cylinder, and check the leakage rate of the cylinder.

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