ELECTROSLAG WELDING MACHINE

• US 3,777,106 A
• Filed: 06/13/1972
• Issued: 12/04/1973
• Est. Priority Date: 06/13/1972
• Status: Expired due to Term

• Current Assignee: Albert W. Nuccel
• Original Assignee: Albert W. Nuccel
• Inventors: Nuccel, Albert W.
• Primary Examiner(s): Staubly, R. F.
• Assistant Examiner(s): Schutzman, L. A.
• Application Number:
  US05/262,191
• Time in Patent Office: 539 Days
• Field of Search: 219/76,6A,137,161
• US Class Current: 219/73.11
• CPC Class Codes: B23K 25/005 Welding for purposes other than joining, e.g. built-up welding

Abstract

An electroslag welding machine for depositing or casting a layer of metal onto an article, comprising a frame means having means thereon for supporting an article, welding electrode means carried on a first movable portion of the frame means and disposed in close proximity to said article for depositing weld metal onto said article, cooling and shaping means carried on a second movable portion of the frame means spaced from the first movable portion and disposed in closely spaced relationship to said article to define a space therebetween, the welding electrode means extending into the space between the article and the cooling and shaping means, and drive means carried by the frame means and connected to at least one of said movable portions to cause movement thereof, said first and second movable portions being connected together for movement in unison to thus cause movement of said welding electrode means and said cooling and shaping means together relative to the article to deposit weld metal on the article and to cool and shape the weld metal deposited on said article.

Claims

1. An electroslag welding machine for depositing a layer of metal onto an article, comprising a base, a frame means supported on the base, an article support pedestal on the base for supporting an article thereon with the axis of the article vertically disposed, a fixed, roof platform secured on top of said frame means, a telescopic upper support secured on said roof platform and extending vertically downwardly therefrom into supporting engagement with the upper end of the article, a first, movable, upper platform supported on said frame means below said fixed roof platform for vertical movement relative to the frame means, welding means carried on said upper movable platform, said welding means disposed in close proximity to said article for depositing weld metal onto said article, a second, movable, lower platform supported on said frame means in vertically spaced relationship below said first movable platform, elongate spacer means releasably connected at opposite ends thereof to said upper and lower movable platforms releasably securing said platforms together in said vertically spaced relationship to permit vertical adjustment of the spacing between the platforms, cooling and shaping means carried on said lower movable platform, said cooling and shaping means disposed in closely spaced relationship to said article to define a space between the article and the cooling and shaping means, the welding means including welding electrode means extending into the space between the article and the cooling and shaping means, and drive means carried by the roof platform and connected to only said upper movable platform to cause vertical movement of said upper and lower movable platforms in unison to thus cause vertical movement of said welding electrode means and said cooling and shaping means together relative to the article to deposit weld metal on the article, and to cool and shape the weld metal deposited on said article.

2. An electroslag welding machine for depositing weld metal onto an article, comprising a base, frame means supported on said base, means on said base for supporting an article thereon, a vertically movable platform carried by the frame means, a welding electrode support means carried by the platform, said electrode support means including an annular oscillating ring supported on the underside of said platform for vertical movement therewith and oscillating movement relative thereto about a vertical axis, a radially extending annular flange on the peripheral marginal edge of said oscillating ring, a plurality of horizontal rollers secured to the underside of said platform and engaged with the underside of said flange to support said oscillating ring on the underside of said platform, a plurality of vertical rollers secured to the underside of said platform and engaged with the outer peripheral edge of said flange to maintain the position of said oscillating ring relative to the center of said platform, a flexible drive means operatively engaged in at least partially surrounding relationship with the peripheral marginal edge of said oscillating ring, reversible motor means operatively connected to said flexible drive means to impart movement thereto and thus to said ring, control means operatively connected with said reversible motor means to cause reverse operAtion of said motor means and thus said flexible drive means and oscillating ring in a second direction after a predetermined amplitude of operation thereof in a first direction, electrode support bracket means carried by said oscillating ring, welding electrode means supported by the electrode support bracket means for movement therewith, said welding electrode means disposed closely adjacent said article for both vertical and oscillating movement relative thereto as said platform is moved vertically and said ring is oscillated, to deposit weld metal on the article, and cooling and shaping means disposed closely adjacent said article to cool and shape the weld metal deposited on the article.

3. An electroslag welding machine for depositing metal onto an article, comprising a base means, a frame means supported on the base means, means on said base means for supporting an elongate, cylindrical steel mill roll thereon with the axis thereof extending vertically, a first movable platform supported on said frame means, welding means carried by said first movable platform for depositing weld metal on said article, a second movable platform supported on said frame means, and a cylindrical cooling and shaping means supported on said second movable platform with its axis substantially vertically disposed and positioned closely adjacent said roll in surrounding relationship thereto for cooling and shaping weld metal deposited on said article, said cooling and shaping means having opposite ends and a plurality of separate, helical coolant water passage means therein extending at least partially therearound and extending from one end to the other end thereof, inlet means communicating with each of the passage means at one end of the cooling and shaping means, and outlet means communicating with each of the passage means at the other end of the cooling and shaping means, to effect circulation of coolant water through each of said passage means from said one end to the other end of said cooling and shaping means thus to cool a molten puddle of weld metal deposited on said article between the article and the cooling and shaping means as said second movable platform and cooling and shaping means are moved vertically relative to said article.

4. An electroslag welding machine for depositing a layer of metal onto an article, comprising a frame means having a top and bottom, a centering device and base support means adjacent the bottom of said frame means for supporting and article thereon in centered relationship in said frame means, a top support and centering means carried by the frame means adjacent the top of said frame means for engaging said article at an upper portion thereof to maintain said article in a centered position in said frame means,said top support means including a first cylindrical portion secured to an upper portion of the frame means and extending vertically downwardly therefrom, said first cylindrical portion being laterally adjustable relative to said frame means for alignment of said top support means relative to said frame means and an article supported therein, a second, telescoping, cylindrical portion telescopically engaged with the first cylindrical portion for vertical adjustment relative thereto and to an article supported in the frame means for operative engagement and disengagement with articles of different vertical dimension, a chuck type adaptor secured to the lower end of said telescoping portion of said top support means for engaging and supporting articles of different horizontal dimension in centered relationship in said machine, welding means carried by a movable portion of the frame means for movement relative to the article, and cooling and shaping means carried by a movable portion of the frame means and disposed in closely spaced relationship to said article to define a space therebetween, said welding means including welding electrode means extending into said space into close proximity with said article to deposit weld metal on said articLe, and said cooling and shaping means being movable relative to said article to cool and shape the weld metal deposited thereon.

5. An electroslag welding machine for depositing weld metal onto an outer surface of an elongate article, comprising a base, a frame means supported on said base, means on said base for supporting said article thereon with the axis of the article vertically disposed, said frame means including a first vertically movable portion, welding means carried on said first vertically movable portion and positioned to deposit weld metal on said article, said frame means including a second vertically movable portion, a cooling and shaping means closely adjacent said article in coaxial surrounding relationship thereto to cool and shape the weld metal deposited on the article, said cooling and shaping means comprising a tubular, water cooled cooling ring, support means supporting said cooling and shaping means on said second vertically movable portion, said support means including a tubular cooling ring support bracket having upper and lower open ends and secured at the lower end thereof on said second vertically movable portion in coaxial, surrounding relationship with a lower end portion of the article, a cooling ring holder bracket having upper and lower open ends and secured at its lower end on the upper end of the cooling ring support bracket in coaxial alignment therewith and in coaxial, surrounding relationship with a lower end portion of said article, said cooling ring supported substantially concentrically within said cooling ring holder bracket and in close, surrounding relationship to said article.

6. An electroslag welding machine for depositing a layer of metal onto an article, comprising a frame means having a top and bottom, a centering device and base support means adjacent the bottom of said frame means for supporting said article thereon in centered relationship in said frame means, an upper support and centering means carried by the frame means adjacent the top of said frame means for engaging said article at an upper portion thereof to maintain said article in a centered position in said frame means, said upper support means being adjustable to accommodate articles of different size, welding means carried by the frame means for movement relative to the article, cooling and shaping means disposed in closely spaced relationship to said article to define a space therebetween, said welding means including welding electrode means extending into said space into close proximity with said article to deposit weld metal on said article, said cooling and shaping means being movable relative to said article to cool and shape the weld metal deposited thereon, and transfer means for transferring an article from a location remote from said frame means into position within said frame means and onto said centering device and base support means, said transfer means comprising a wheeled vehicle, support means on said wheeled vehicle for supporting said article thereon, said wheeled vehicle having spaced apart portions defining a space therebetween, said spaced apart portions adpated to extend on either side beyond said centering device and base support means to position an article supported on the wheeled vehicle in vertical alignment with the base support means, and lift means connected with said support means on said wheeled vehicle to lower the article onto said base support means and to lift it therefrom.

7. An electroslag welding machine as in claim 1, wherein said frame means includes four spaced apart, vertically extending, parallel support columns, said roof platform secured on the upper ends of said support columns, and said upper and lower platforms slidably arranged on said support columns for vertical movement relative thereto.

8. An electroslag welding machine as in claim 7, wherein said drive means comprises motor means, and means connected between said motor means and said upper platform for raising and lowering said upper platform.

9. An electroslag welding machine as in claim 8, wherein said drive means is secured on top of the roof platform, and lift screw means are connected with said upper platform and extend vertically upwardly to said roof platform, said motor means being connected with said lift screw means through suitable gear means for raising and lowering said upper platform.

10. An electroslag welding machine as in claim 9, wherein said lower platform is releasably connected to said upper platform through said spacer means, and said spacer means comprises a plurality of spacer columns releasably connected at their opposite ends to the upper and lower platforms, respectively.

11. An electroslag welding machine as in claim 1, wherein said welding electrode means are carried on an oscillator ring, said oscillator ring being connected to the upper platform for oscillating movement relative thereto.

12. An electroslag welding machine as in claim 11, wherein drive means is carried by said upper platform and operatively connected with said oscillator ring for causing oscillation of said oscillator ring and said welding electrode means carried thereby.

13. An electroslag welding machine as in claim 12, wherein said drive means includes reversible motor means and drive chain means connected between said motor means and said oscillator ring, and motor control means operatively connected with said chain means and said motor means for causing reverse operation of said motor means and movement of said chain means and said oscillator ring in a second direction after a predetermined amplitude of oscillation of said oscillator ring in a first direction.

14. An electroslag welding machine as in claim 13, wherein said control means comprises a sprocket engaged with said chain means, limit switch engaging means adjacent said sprocket means and connected with said sprocket means for movement therewith, limit switch means adjacent said limit switch engaging means in a position to be engaged by said limit switch engaging means upon predetermined movement thereof to determine the amplitude of oscillation of the oscillator ring.

15. An electroslag welding machine as in claim 14, wherein said welding means includes welding wire supply means on top of said upper platform, welding wire feed means connected to said oscillator ring for feeding said welding wire, and guide means connected to the wire feed means and positioned to guide the welding wire fed by the wire feed means into the space between the cooling and shaping means and the article.

16. An electroslag welding machine as in claim 15, wherein said wire feeding means and said electrode means are adjustably carried by said oscillator ring for vertical and lateral adjustment relative thereto and to said article.

17. An electroslag welding machine as in claim 1, wherein said article support pedestal has centering means thereon for supporting an article in centered relationship in said machine.

18. An electroslag welding machine as in claim 6, wherein said upper centering and support device includes a telescoping means which moves vertically up and down into and out of engagement with said article, said telescoping means enabling said upper centering and support device to accommodate different size articles.

19. An electroslag welding machine as in claim 18, wherein said article comprises an elongate, solid, cylindrical steel mill roll supported in said machine with the axis thereof extending vertically, and said lower platform has an entry slot through one side thereof to enable said roll to be positioned in the machine.

20. An electroslag welding machine as in claim 19, wherein said cooling and shaping means comprises a mold means positioned around said roll for cooling and shaping the weld metal deposited on the roll.

21. An electroslag welding machine as in claim 20, wherein said mold means is supported on top of said lower platform in surrounding relationship to said roll and includes a cooling ring support bracket attAched to the lower platform in aligned centered relationship thereto and a cooling ring holder bracket supported on top of said cooling ring support bracket, said cooling and shaping means including a cooling and shaping ring supported inside said cooling ring holder bracket.

22. An electroslag welding machine as in claim 21, wherein said cooling and shaping means is water cooled and has a plurality of separate water coolant passages therein extending from the upper end to the lower end thereof.

23. An electroslag welding mahcine as in claim 3, wherein said cooling and shaping means comprises an inner cylinder having a tapered inner surface and a plurality of helical grooves or channels in the outer surface thereof, and an outer cylinder or sleeve welded or otherwise suitably secured over the outer surface of said inner cylinder for closing said grooves or channels to define a plurality of separate helical water passageways having inlets at the top of said cooling and shaping means and outlets at the bottom thereof.

24. An electroslag welding machine as in claim 23, wherein a separate insert is fitted within said inner cylinder of said cooling and shaping means, said insert having a cylindrical inner surface and a tapered outer surface of substantially the same size and shape as the tapered inner surface of said inner cylinder.

25. An electroslag welding machine as in claim 24, wherein said insert is formed of copper.

26. An electroslag welding machine as in claim 25, wherein said inner cylinder is formed of copper.

27. An electroslag welding machine as in claim 21, wherein said cooling ring holder bracket has a plurality of vertically extending slots therein opening upwardly through the upper end thereof, and a plurality of relatively short pipe fittings or nipples are connected with the inlets and outlets of said water passageways, said pipe fittings or nipples being received in said slots in said cooling ring holder bracket.

28. An electroslag welding machine as in claim 21, wherein conduit means are connected with said inlet pipe fittings or nipples and with an inlet header or manifold adjacent one edge of the lower platform, and conduit means are connected with the outlet pipe fittings or nipples and with an outlet header or manifold adjacent said inlet header or manifold at said one edge of said lower platform.

29. An electroslag welding apparatus as in claim 2, wherein said oscillating ring has a plurality of radially extending slots therein, said welding electrode support means are adjustably connected to said slots for movement therealong to adjust the radial position of said welding electrode means for accommodating articles of different size in said machine.

30. An electroslag welding apparatus as in claim 29, wherein said welding electrode support means is vertically adjustable relative to said oscillating ring and said article.

31. An electroslag welding apparatus as in claim 30, wherein welding wire supply means are supported on top of said upper platform for supplying welding wire to said welding electrode means, said welding wire being supported on wire guides on the upper platform for preventing crimping of the welding wire as it is fed from said supply means to said welding electrode means.

32. An electroslag welding apparatus as in claim 31, wherein wire feed means are mounted on said electrode support means for feeding the welding wire from the supply means to the electrode means.

33. An electroslag welding apparatus as in claim 32, wherein said cooling and shaping means is water cooled and includes a cooling ring having a plurality of helical water passages therein extending from the top to the bottom thereof, and water inlet and outlet means connected with the water passages adjacent the top and bottom thereof, respectively.

34. An electroslag welding apparatus as in claim 4, wherein said frame means includes a roof platform, said top support means being carried by the roof platform adjacent the center thereof.

35. An electroslag welding apparatus as in claim 34, wherein said upper portion of said top support means is adjustably fixed to the underside of said roof platform and extends vertically downwardly therefrom, said telescoping portion being telescopically received inside said first cylindrical portion, and drive rod means connected with the upper end of said telescoping portion and extending longitudinally through said first cylindrical portion to above said roof platform and connected to suitable drive means for raising and lowering said telescoping portion of said top support means.

36. An electroslag welding machine as in claim 35, wherein said telescoping portion extends downwardly through an opening in the center of an upper platform carried by said frame means, said welding electrode means being carried by said upper platform.

37. An electroslag welding machine as in claim 2, wherein said electrode support bracket means includes means for vertical and lateral adjustment of said bracket means and electrode means relative to said oscillating ring and said article.

38. An electroslag welding machine as in claim 37, wherein said welding electrode support means further includes wire feed means for feeding welding wire from a supply means carried on said platform to said welding electrode means.

39. An electroslag welding machine as in claim 2, wherein said flexible drive means comprises a chain means disposed in surrounding relationship to the marginal edge of said oscillating ring and secured to said oscillating ring at least at one point thereof.

40. An electroslag welding machine as in claim 39, wherein said reversible motor means is connected with said chain means through a worm gear reducer.

41. An electroslag welding machine as in claim 40, wherein said control means includes limit switch means operatively associated with said chain means for sensing the amplitude of oscillation of said oscillating ring to effect switching of said reversible motor from one direction of movement to another direction of movement upon a predetermined amount of travel of said chain means and oscillating ring.

42. An electroslag welding machine as in claim 41, wherein said control means includes a housing, a first axle disposed adjacent one side of said housing, a sprocket wheel mounted for rotation about the first axle and engaged with said chain means so that movement of said chain means causes rotation of said sprocket wheel, a second axle mounted in said housing spaced from said first axle, a second wheel mounted for rotation about said second axle, belt means engaged with a hub means on said sprocket wheel and with a hub means on said second wheel for causing rotation of said second wheel along with rotation of said sprocket wheel, and a pair of circumferentially spaced limit switch engaging means carried by said second wheel in a position to engage a respective one of a pair of limit switches mounted at opposite sides of said housing.

43. An electroslag welding machine as in claim 42, wherein a pair of substantially identical power units are connected with said reversible motor means to provide a fail safe arrangement so that in the event one of said power units fails, the other power unit is effective to continue operating said oscillating ring.

44. An electroslag welding machine as in claim 43, wherein said reversible motor means comprises a dual vane hydraulic motor.