Automatic welding method for double-layer dense grid stiffening wallboard cable bent tower steel shell block

Abstract

The invention belongs to the technical field of bridge construction, and particularly relates to an automatic welding method for double-layer dense grid stiffening wall plate cable bent tower steel shell blocks. The method includes cutting and preparing materials; vertical ribs, transverse ribs and anchoring steel plates are sequentially assembled on the steel wall plates to form wall plate units, and the wall plate units are fixed to the welding platform; programming input is conducted on welding operation; a double-arm robot welding system is combined with consumable electrode gas shielded welding equipment to weld the wallboard units with the same size; shear nails are welded at the stiffening centers of the grids formed by the transverse ribs and the vertical ribs; and a dragging robot is combined with shielded welding equipment to be matched with a constraint tool to weld vertical penetration corner angle welding seams among the wall plate units in sequence. According to the method, the problems of high labor intensity and low construction efficiency of manual welding of the double-layer dense grid stiffening wall plate cable bent tower steel shell block are solved, the welding construction efficiency is remarkably improved, the manufacturing period is greatly shortened, the welding quality stability and the overall post-welding precision are guaranteed, and green and low-carbon transformation of the bridge construction technology is accelerated.

Description

Technical Field

[0001] The invention belongs to the technical field of bridge construction, and in particular relates to an automated welding method for a double-layer dense grid stiffening wall panel cable tower steel shell block. Background Art

[0002] Create a green development chain for the entire bridge construction industry chain. The steel-shell concrete composite structure bridge tower fully utilizes the advantages of reinforced concrete bridge towers, such as high compressive strength, low cost, convenient construction, low cracking in the anchoring area, and good durability. It has been widely promoted and applied in domestic bridge design.

[0003] The steel wall panels of conventional steel shell concrete bridge towers are provided with vertical ribs and transverse ribs, which are crisscrossed and form a grid reinforcement with a size of 600x600mm. There are two methods for making steel shell wall panel units using traditional processes. Method 1: Assemble and position the vertical ribs and transverse ribs on the steel wall panels together, and use intensive manual welding. This not only has high labor intensity and low construction efficiency, but also has poor welding quality stability and plate unit post-welding accuracy. Method 2: First, only assemble and position the vertical ribs on the steel wall panels, and use a gantry welding machine to complete the welding of the vertical ribs, and then assemble and position the transverse ribs for the second time, and use intensive manual welding for the transverse ribs. However, after the vertical ribs are welded, the steel wall panels will have obvious longitudinal and transverse welding deformations, which are difficult to completely eliminate through thermal correction, making the secondary assembly of the transverse ribs extremely difficult. A large number of flame cutting of the transverse rib notches is required to complete the assembly, which has low construction efficiency and poor product appearance quality. Moreover, after the secondary assembly of the transverse ribs, it is impossible to achieve automatic welding through a gantry welding machine. The above two traditional processes have not fundamentally solved the difficult problem of high labor intensity and low construction efficiency of manual welding of steel shell wall panel units.

[0004] A Yangtze River Bridge is a world-leading large-span highway cable-stayed bridge. Its cable tower adopts a steel shell concrete composite structure. The tower column adopts a hollow thin-walled box section. The vertical and horizontal ribs on the steel shell wall are crisscrossed to form a grid reinforcement with a size of 400x400mm. Compared with conventional designs, the grid reinforcement is extremely narrow and dense. At the same time, each double-layer dense grid stiffening wall panel cable tower steel shell block is equipped with 12 angular welds, which makes the welding workload of the cable tower steel shell block extremely large. Therefore, improving the welding automation rate of the double-layer dense grid stiffening wall panel cable tower steel shell block, controlling its welding quality stability and ensuring the post-welding accuracy of the cable tower steel shell block are key technologies in the green construction of steel bridge towers, and have also become major problems that need to be solved urgently. Summary of the invention

[0005] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide an automated welding method for a double-layer dense grid stiffening wall panel tower steel shell block, which is used to solve the problem of low welding construction efficiency. The technical solution of the present invention to solve the above technical problems is as follows: an automated welding method for a double-layer dense grid stiffening wall panel tower steel shell block, comprising the following steps: S1. Cutting and preparation of materials: steel wall panels, anchoring steel plates, vertical ribs and transverse ribs; S2. After assembling the vertical ribs, the transverse ribs and the anchoring steel plates on the steel wall panels in sequence to form a wall panel unit, the wall panel unit is fixed on the welding platform; S3. Program and input welding operations through online programming of the teaching pendant, including: S301, taking the weld in the center area of ​​the steel wall panel as the starting point, welding the vertical ribs one by one from the middle to both sides, and inputting the coordinate points of the vertical fillet welds between the vertical ribs and the transverse ribs into the welding system; S302, taking the weld in the center area of ​​the steel wall panel as the starting point, welding the vertical ribs one by one from the middle to both sides, and inputting the coordinate points of the flat angle fillet weld between the vertical rib and the steel wall panel into the welding system; S303, taking the weld in the center area of ​​the steel wall panel as the starting point, welding the transverse ribs one by one from the middle to both sides, and inputting the coordinate points of the flat angle fillet weld between the transverse rib and the steel wall panel into the welding system; S304, taking the short focus of the anchoring steel plate as the starting point and performing symmetrical welding from the short focus to the long focus, inputting the coordinate points of the flat corner fillet weld between the anchoring steel plate and the steel wall plate into the welding system.

[0006] S4, automatically welding the wall panel units of the same size according to the data saved in step S3; S5. Weld shear studs at the center of the grid reinforcement formed by the transverse and vertical ribs; S6, cutting the peripheral margin of the wall panel unit and welding the groove, and tying the transverse ribs and vertical ribs to form a steel mesh; S7. Use the wall panel units to assemble in sequence to form inner wall panel units and outer wall panel units, assemble the supporting angle steel between the inner wall panel units and the outer wall panel units, and use the restraint tooling to weld the inner wall panel units and the outer wall panel units in sequence with standing penetration corner welds.

[0007] Compared with the prior art, the above technical solution has the following beneficial effects: Through a specific welding sequence, the welding construction efficiency of the double-layer dense grid stiffening wall panel tower steel shell block is significantly improved, the production period is greatly shortened, and the welding quality stability and overall post-welding accuracy are more effectively guaranteed, which effectively promotes the application of automated welding technology in steel bridge manufacturing and accelerates the transformation of bridge construction technology to green and low-carbon.

[0008] Based on the above technical solution, the embodiment of the present application can also be improved as follows: In one embodiment, the assembly of the wall panel unit in step S2 is specifically as follows: Place the steel siding flat on the flat frame, and use the vertical and horizontal baselines of the siding as the reference to mark the vertical and horizontal rib assembly position lines. Use the vertical rib assembly position lines as the reference to position and assemble the vertical ribs, and adjust and control the vertical rib position within an appropriate range; Use the assembly position line of the transverse rib as a reference to position and assemble the transverse rib, control the transverse rib to be in a suitable position, and check and control that the steel bar holes in the same row on the transverse rib and vertical rib correspond to a straight line; Using the center line of the steel wall panel anchor hole as a reference, position and assemble the anchor steel plate.

[0009] In one embodiment, the welding of the shear studs in step S5 is specifically as follows: First, the rigid constraint between the wall panel unit and the frame after the grid reinforcement welding is completed is released, the flatness of the wall panel unit is adjusted by heat correction, the wall panel unit is placed flat on the welding platform with the ribbed side facing up, the long side of the steel wall panel is ensured to be parallel to the walking direction of the welding machine, and the constraint tooling is used to rigidly fix it around the frame; Taking the weld in the center area of ​​the steel wall panel as the starting point, welding is carried out row by row from the middle to both sides, and the stud welding system is used to complete the welding of the shear studs in the grid formed by the transverse ribs and vertical ribs.

[0010] In one embodiment, before step S3, when the vertical ribs, transverse ribs and anchoring steel plates are tack welded at a flat angle, the weld leg size of the tack weld is less than 3 mm, the length of the tack weld is 35-50 mm, and the spacing of the tack welds is 300-350 mm.

[0011] In one embodiment, at least 100 mm of non-weld area is reserved at both ends of the flat-angle fillet welds between the vertical ribs, transverse ribs and steel wall panels in step S3. The end non-weld areas reserved between the vertical ribs and the steel wall panels are welded when the steel shell segments are pre-assembled, and the non-weld areas reserved between the transverse ribs and the steel wall panels are welded when the steel shell blocks are assembled.

[0012] In one embodiment, in step S7, the inner wall panel unit and the outer wall panel unit are formed by sequentially assembling the wall panel units, and the supporting angle steel is assembled between the inner wall panel unit and the outer wall panel unit, specifically: The qualified wall panel units are assembled in sequence to form inner wall panel units. The inner vertical panel units are placed on the segment assembly frame, and are positioned based on the ground sample line to control the top and bottom opening sizes of the inner wall panel units. After passing the inspection, they are fixed to the frame; The qualified wall panel units are assembled in sequence to form the outer wall panel units. The outer wall panel units are placed upright on the segment assembly frame. The outer wall panel units are positioned based on the ground sample line and the positioned inner wall panel units. The top and bottom sizes of the outer wall panel units and the spacing between the inner and outer wall panels are controlled. After the test is qualified, they are fixed with the frame and the inner wall panel. The supporting angle steels are assembled sequentially from top to bottom between the inner wall panel units and the outer wall panel units.

[0013] In one embodiment, in step S7, the inner wall panel unit and the outer wall panel unit are welded in sequence by using a restraining tool, specifically: The inner and outer wall panel units are controlled by constraint tooling, and a single-sided welding and double-sided forming welding process is adopted. The vertical penetration corner welds between the wall panels of the inner wall panel unit are welded in sequence first, and then the vertical penetration corner welds between the wall panels of the outer wall panel unit are welded in sequence.

[0014] In one embodiment, when the inner layer wall panel unit and the outer layer wall panel unit are subjected to standing penetration corner welding in step S7, the corner welds of at least 15% of the length of the top are welded first, and then the remaining welds are welded from bottom to top. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0016] Figure 1 It is a schematic diagram of the structure of the steel shell block of the double-layer dense grid stiffening wall panel cable tower in the present invention.

[0017] Figure 2 It is a schematic diagram of the structure of the wall panel unit in the present invention.

[0018] Figure 3 It is a schematic diagram of the welding process of the wall panel unit in the present invention.

[0019] Figure 4 It is a schematic diagram of the welding sequence of the wall panel unit in the present invention for one-time welding programming.

[0020] Figure 5 It is a schematic diagram of the welding sequence for secondary welding programming of the wall panel unit in the present invention.

[0021] Figure 6 It is a schematic diagram of the welding sequence of three welding programming of the wall panel unit in the present invention.

[0022] Figure 7 It is a schematic diagram of the welding sequence of the wall panel unit for four welding programmings in the present invention.

[0023] Figure 8It is a schematic diagram of the welding process of the double-layer dense grid stiffening wall panel tower steel shell block in the present invention.

[0024] Fig. 9 The schematic diagram of the welding groove of the through-penetration corner weld between the steel shell block wall panels of the double-layer dense grid stiffening wall panel cable tower in the present invention is shown.

[0025] Fig.10 It is a schematic diagram of the welding sequence of the steel shell blocks of the double-layer dense grid stiffening wall panel tower in the present invention.

[0026] Fig.11 It is a schematic diagram of the automated welding of the full penetration corner welds between the steel shell block wall panels of the double-layer dense grid stiffening wall panel cable tower in the present invention.

[0027] Fig.12 This is a perspective view of the automated welding of the wall panel unit in the present invention.

[0028] Fig.13 This is a front view of the wall panel unit during automatic welding in the present invention.

[0029] Fig.14 This is a close-up photo of the automated welding of the wall panel unit in the present invention.

[0030] Fig.15 It is a front view of the automated full penetration corner welds between the steel shell block panels of the double-layer dense grid stiffening wall panel cable tower in the present invention.

[0031] Fig.16 This is a close-up physical picture of the automation of the full penetration corner welds between the block wall panels of the double-layer dense grid stiffening wall panel cable tower steel shell in the present invention.

[0032] Figure numerals: 1. Double-layer dense grid stiffened wall panel tower steel shell block; 2. Inner wall panel unit; 3. Angle steel; 4. Outer wall panel unit; 5. Wall panel unit; 6. Steel wall panel; 7. Vertical rib one; 8. Vertical rib two; 9. Transverse rib one; 10. Transverse rib two; 11. Anchor steel plate; 12. Shear nails; 13. Double through-line anchor holes; 14. Rebars; 15. Penetration angle welds. DETAILED DESCRIPTION

[0033] The following embodiments of the technical solution of the present invention are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore only used as examples, and cannot be used to limit the protection scope of the present invention. It should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should have the common meanings understood by those skilled in the art to which the present invention belongs.

[0034] In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0035] In this application, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0036] In the long-span highway cable-stayed bridge, the cable tower adopts a steel shell concrete composite structure. The tower column adopts a hollow thin-walled box section as a whole, and the tower column section is a large-angle diamond hexagonal section, which has the advantages of being wind-resistant, having a prominent three-dimensional sense, and having a strong symbolic effect. It is similarly used in the Guanyin Temple Yangtze River Bridge. However, the maximum length of the steel shell wall is 8 meters and the maximum width is 4 meters. The vertical ribs and transverse ribs on the steel shell wall are crisscrossed to form a grid reinforcement with a size of 400x400mm. Compared with the conventional design, the grid reinforcement is extremely narrow and dense. At the same time, each double-layer dense grid stiffening wall panel cable tower steel shell block is equipped with 12 corner welds, which makes the welding workload of the cable tower steel shell block extremely large.

[0037] like Figure 1-2 As shown, the double-layer dense grid stiffened wall panel tower steel shell block in the present invention includes an inner wall panel unit, a supporting angle steel, and an outer wall panel unit, and the inner wall panel unit and the outer wall panel unit are connected by supporting angle steel; the inner wall panel unit and the outer wall panel unit are each composed of 6 wall panel units; the maximum length of the wall panel unit is 8 meters and the maximum width is 4 meters, and the wall panel unit includes a steel wall panel, vertical rib one, vertical rib two, transverse rib one, transverse rib two, anchor steel plates, shear nails, and steel bars.

[0038] Specifically, the steel wall plate and the anchoring steel plate are provided with elliptical double-through-line anchor holes, and the double-through-line anchor holes between the two must be aligned. The short side direction of the steel wall plate is along the tower height direction, and the long side direction is perpendicular to the tower height direction. The long side direction of the vertical rib 1 and the vertical rib 2 is the tower height direction, and the long side direction of the transverse rib 1 and the transverse rib 2 is perpendicular to the tower height direction. The transverse rib 1 and the transverse rib 2 are provided with notches to ensure the continuous passage of the vertical ribs. The bottom of the notch is provided with a left-right symmetrical C15 over-welding cutting angle, and the notch width is opened according to the theoretical size + 2mm. The vertical ribs and transverse ribs are provided with equidistant steel bar holes, and the distance between the lower edge of the steel bar hole and the steel wall plate is not less than 25mm.

[0039] The vertical ribs and the transverse ribs on the steel wall panels are crisscrossed to form a 400x400mm grid reinforcement, and the shear nails are grouped in two and are equidistantly distributed in the center of the grid reinforcement.

[0040] The transverse rib 1, transverse rib 2, vertical rib 1 and vertical rib 2 are provided with equidistant steel bar holes for passing transverse and vertical steel bars. The transverse rib 2 and vertical rib 2 are provided with trapezoidal bosses for overlapping the angle steels between the wall panels. At least one vertical rib 2 is provided, and the transverse rib 1 and the transverse rib 2 are arranged alternately.

[0041] The two short sides of the vertical ribs 1 and 2 are provided with bolt holes. When the steel shell is installed on site, the vertical ribs of the upper and lower steel shells are connected by bolts. The two short sides of the transverse ribs are provided with butt grooves. When the steel shell segments are assembled, the transverse ribs of the same layer of steel shells are connected by welding.

[0042] The vertical ribs and steel wall panels are connected by double-sided fillet welds with a weld foot size of 8mm, the transverse ribs and steel wall panels are connected by double-sided fillet welds with a weld foot size of 6mm, the vertical ribs and transverse ribs are connected by double-sided fillet welds with a weld foot size of 6mm, and the anchor steel plate and steel wall panel are connected by a single-sided fillet weld with a weld foot size of 12mm. The inner wall panel unit and the outer wall panel unit are both composed of 6 wall panel units, and the wall panel units are connected by full penetration corner welds.

[0043] The present invention provides an automatic welding method for a double-layer dense grid stiffening wall panel cable tower steel shell block, comprising the following steps: S1. Cutting and preparation: steel wall plates, anchor steel plates, vertical ribs and transverse ribs. The steel wall plates are provided with elliptical double-through-line anchor holes. The anchor steel plates are cut by a tube-sheet intersecting cutting machine. The intersecting cutting machine gun head can automatically adjust the cutting angle to ensure that the oblique elliptical anchor holes are cut and formed in one time. The vertical ribs and transverse ribs are cut by CNC cutting machines, and steel bar holes, bolt holes and welding holes are flame-cut on the vertical ribs and transverse ribs.

[0044] S2. After assembling the vertical ribs, the transverse ribs and the anchoring steel plates on the steel wall panels in sequence to form a wall panel unit, the wall panel unit is fixed on the welding platform; like Figure 3 As shown, the assembly of the wall panel unit in step S2 is specifically as follows: Place the steel siding flat on the flat frame, mark the vertical rib and transverse rib assembly position lines based on the vertical and horizontal baselines of the siding, position and assemble the vertical ribs based on the vertical rib assembly position lines, and adjust the vertical rib position to be within a suitable range. Specifically, adjust the vertical rib to be no more than 2mm with the steel siding, and the distance between the upper and lower vertical ribs is no more than 1mm; Use the assembly position line of the transverse rib as the reference to locate and assemble the transverse rib, control the transverse rib to be in the appropriate position, and specifically control the transverse rib angle to be consistent with the requirements. After the transverse rib is assembled, it is necessary to use the inspection template to check the angle, and check and control the transverse ribs. The steel bar holes in the same column on the vertical ribs correspond to a straight line. Specifically, use straight round tubes to check the steel bar holes on the transverse ribs and vertical ribs to ensure that the steel bar holes in the same vertical column and the same horizontal column are in a straight line to avoid errors; Using the center line of the steel wall panel anchor hole as a reference, position and assemble the anchor steel plate.

[0045] Before step S3, when the vertical ribs, transverse ribs and anchoring steel plates are positioned and welded at a flat angle, the weld leg size of the positioning weld is less than 3 mm, the length of the positioning weld is 35-50 mm, and the spacing of the positioning weld is 300-350 mm. Specifically, solid welding wire CO2 gas shielded welding is used for positioning welding. The gas shielded welding welding material is solid welding wire G49A3UC1S6 (φ1.0 mm), the welding current is 210-230 A, the arc voltage is 22-24 V, the welding speed is 360-380 mm / min, the dry extension is 12-16 mm, and the gas flow rate is 15-20 L / min.

[0046] Before programming is entered through the teach pendant, the assembled wall panel unit is hoisted onto the special welding platform. When placing it, ensure that the long side of the steel wall panel is parallel to the travel direction of the gantry of the welding machine, and use restraint tooling to rigidly fix it around the frame.

[0047] S3. Program and input welding operations through online programming of the teaching pendant, including: S301. One-time welding programming: Taking the weld in the center area of ​​the steel wall plate as the starting point, the vertical ribs are welded one by one from the middle to the two sides. The coordinate points of the vertical fillet welds between the vertical ribs and the horizontal ribs are entered into the welding system. When the vertical fillet welds between the vertical ribs and the horizontal ribs are welded automatically, the robot control program calls the automatic pulse argon-rich gas shielded welding mode. The gas shielded welding material is solid welding wire G55A4UC1ZSN2 (φ1.2mm), the shielding gas is 80% Ar and 20% CO2 by volume, the welding current is 170-190A, the arc voltage is 23-25V, the welding speed is 90-100mm / min, the dry extension is 10-16mm, the gas flow is 20-25L / min, the arc swing mode is an ascending crescent shape, the swing width is 5-6mm, the swing frequency is 50-55 times / min, and the left and right stops are both 0.6s; S302, secondary welding programming: take the weld in the center area of ​​the steel wall plate as the starting point, weld the vertical ribs one by one from the middle to both sides, enter the coordinate points of the flat angle fillet weld between the vertical rib and the steel wall plate into the welding system, and when the flat angle fillet weld between the vertical rib and the steel wall plate is automatically welded, the robot control program calls the automatic pulse argon-rich gas shielded welding mode, the gas shielded welding material is solid welding wire G55A4UC1ZSN2 (φ1.2mm), the shielding gas is 80% Ar and 20% CO2 by volume, the welding current is 250-270A, the arc voltage is 26-28V, the welding speed is 270-280mm / min, the dry extension is 10-16mm, the gas flow is 20-25L / min, the swing arc mode is sinusoidal, the swing width is 7-9mm, the swing frequency is 95-100 times / min, and the left and right stops are both 0.4s; S303, three-time welding programming: take the weld in the center area of ​​the steel wall plate as the starting point, weld the transverse ribs one by one from the middle to the two sides, enter the coordinate points of the flat angle fillet weld between the transverse rib and the steel wall plate into the welding system, and when the flat angle fillet weld between the transverse rib and the steel wall plate is automatically welded, the robot control program calls the automatic pulse argon-rich gas shielded welding mode, the gas shielded welding welding material is solid welding wire G55A4UC1ZSN2 (φ1.2mm), the shielding gas is 80% Ar and 20% CO2 by volume, the welding current is 240-260A, the arc voltage is 25-27V, the welding speed is 280-290mm / min, the dry extension is 10-16mm, the gas flow is 20-25L / min, the swing arc mode is sinusoidal, the swing width is 6-8mm, the swing frequency is 90-95 times / min, and the left and right stops are both 0.3s; S304, four-pass welding programming: take the short focus of the anchor steel plate as the starting point, and perform symmetrical welding from the short focus to the long focus. Enter the coordinate points of the flat angle fillet weld between the anchor steel plate and the steel wall plate into the welding system. When the flat angle fillet weld between the anchor steel plate and the steel wall plate is automatically welded, the robot control program calls the automatic pulse argon-rich gas shielded welding mode. The gas shielded welding material is solid welding wire G55A4UC1ZSN2 (φ1.2mm), the shielding gas is 80% Ar and 20% CO2 by volume, the welding current is 270-290A, the arc voltage is 28-30V, the welding speed is 300-310mm / min, the dry extension is 10-16mm, the gas flow is 20-25L / min, the arc swing mode is sinusoidal, the swing width is 8-9mm, the swing frequency is 80-85 times / min, and the left and right stops are both 0.5s.

[0048] like Figure 4-7 As shown in the figure, the welding sequence corresponding to the four welding programming is as follows: Corresponding to one welding programming, schematic diagram Figure 4 A~C in the figure are welded in alphabetical order. Figure 4 1 and 1' are welded synchronously and symmetrically, indicating Figure 4 The (1,1')~(5,5') in the figure are welded in ascending order. First, a vertical rib is welded synchronously and symmetrically in the order of (1,1')~(5,5'), and then the vertical ribs on both sides are welded one by one in the order of letters A~C. Corresponding to secondary welding programming, schematic Figure 5 1 and 1' are welded synchronously and symmetrically, indicating Figure 5 The (1,1')~(5,5') in the figure are welded in ascending order according to the numerical sequence; Corresponding to three welding programming, schematic Figure 6 1 and 1' are welded synchronously and symmetrically, indicating Figure 6 The (1,1')~(5,5') in the figure are welded in ascending order according to the numerical sequence; Corresponding to four welding programming, schematic Figure 7 1 and 1' are welded synchronously and symmetrically, indicating Figure 7 The (1,1')~(2,2') in the figure are welded in ascending order according to the numerical sequence.

[0049] By setting up four procedures, the transverse ribs, vertical ribs, anchor steel plates and steel wall plates are firmly welded to each other, and the welding sequence is gradually from the center to both sides, thus avoiding the problem of difficulty in assembling the transverse and vertical ribs due to gradual welding, and at the same time improving the quality stability.

[0050] The welding system includes: a dual-arm robot welding system and a dragging teaching collaborative robot. The dual-arm robot welding system can adopt a gantry-type RTE 496-S dual-arm robot welding system, which is specifically used for welding the wall panel unit after four welding programming. The dragging teaching collaborative robot can specifically adopt FANUC's CRX-5IA dragging teaching collaborative robot, which is used to complete the automated welding operation of the steel shell block's full penetration corner welds. The gantry-type RTE 496-S dual-arm robot welding system is controlled by online programming through the teaching pendant. It has arc tracking function and high-precision nozzle positioning function. After the weld coordinate point is entered into the system, the precise position of the weld can be automatically found, effectively avoiding the occurrence of wrong welding, off-center welding or the inability to find the weld. The gantry-type RTE 496-S dual-arm robot welding system is combined with the consumable gas shielded welding equipment to complete the automated welding operation of the dense grid reinforcement of the wall panel unit.

[0051] Specifically, the gantry-type RTE 496-S dual-arm robot welding system is equipped with two welding gun nozzles. During welding, the component welds are welded synchronously and symmetrically according to the welding programming. The robot starts the arc at the end of the cross-rib notch and uses the hot arc starting function to achieve secondary fusion of the corner molten pool, ensuring that the sealing weld at the notch is full and beautiful.

[0052] S4. Automatically weld the wall panel units of the same size according to the data saved in step S3. Figure 12-14 As shown, in the subsequent welding of the wall panel units of the same size, step S3 can be directly skipped, step S4 can be used, the teaching pendant is operated, the dual-arm robot welding gun head is returned to the starting positioning point in step S3, and welding is started.

[0053] S5. Weld shear studs at the center of the grid reinforcement formed by the transverse and vertical ribs; like Figure 3 As shown, after the vertical ribs, transverse ribs and anchoring steel plates are welded on the steel wall plate, the shear nails are welded. The specific welding of the shear nails is as follows: First, the rigid constraint between the wall panel unit and the frame after the grid reinforcement welding is completed is released, the flatness of the wall panel unit is adjusted by heat correction, the wall panel unit is placed flat on the welding platform with the ribbed side facing up, the long side of the steel wall panel is ensured to be parallel to the walking direction of the welding machine, and the constraint tooling is used to rigidly fix it around the frame; Taking the weld in the center of the steel siding as the starting point, the welding is performed row by row from the middle to both sides. The stud welding system uses the Taylor CNC fully automatic stud welding system combined with arc stud welding equipment to complete the welding of the shear studs. When the shear studs are welded horizontally and automatically, the welding current is 1500-1800A, the welding time is 1.0-1.1s, the stud extension length is 5-6mm, and the stud lifting length is 3.0-4.0mm. Specifically, the shear studs are welded in the grid formed by the horizontal ribs and vertical ribs.

[0054] S6. Cut the peripheral allowance and welding groove of the wall panel unit. Specifically, first correct the baseline of the wall panel unit, draw the circumferential welding groove line based on the baseline, use a CNC laser trimming machine to flame cut the peripheral allowance and welding groove of the wall panel unit, and then tie the horizontal and vertical steel bars in the horizontal and vertical ribs to form a steel mesh.

[0055] S7. Use the wall panel units to assemble in sequence to form inner wall panel units and outer wall panel units, assemble the supporting angle steel between the inner wall panel units and the outer wall panel units, and use the restraint tooling to weld the inner wall panel units and the outer wall panel units in sequence with standing penetration corner welds.

[0056] Among them, Figure 8 As shown in the figure, from top to bottom, in step S7, the inner wall panel unit and the outer wall panel unit are formed by sequentially assembling the wall panel units, and the supporting angle steel is assembled between the inner wall panel unit and the outer wall panel unit, specifically: First, the qualified wall panel units are assembled in sequence to form the inner wall panel units. The inner vertical panel units are placed on the segment assembly frame, and the ground sample line is used as the reference for positioning. The top and bottom sizes of the inner wall panel units are controlled. After passing the inspection, they are fixed to the frame. Secondly, the qualified wall panel units are assembled in sequence to form the outer wall panel units. The outer wall panel units are placed upright on the segment assembly frame, and the ground sample line and the positioned inner wall panel units are used as references for positioning. The top and bottom opening dimensions of the outer wall panel units and the spacing between the inner and outer wall panels are controlled. After passing the inspection, they are fixed with the frame and the inner wall panels. Finally, assemble and fix the supporting angle steels between the inner wall panel units and the outer wall panel units from top to bottom.

[0057] In step S7, the inner wall panel unit and the outer wall panel unit are welded in sequence by using the restraint tooling, specifically: Since dense steel bars and cylindrical head welding nails are arranged in the inner and outer wall cavities of the steel shell block, the structure in the cavity is complex and there is no welding space, so the penetration corner welds between the wall panels are welded by single-sided welding and double-sided forming welding process, and the welding deformation is controlled by restraining tooling; Firstly, a dragging teaching collaborative robot is used on the segment assembly frame to sequentially weld the vertical penetration corner welds between the wall panels of the inner wall panel unit, and then sequentially weld the vertical penetration corner welds between the wall panels of the outer wall panel unit.

[0058] By dragging the teaching collaborative robot for teaching programming, there is no need to import any drawing information for programming and teaching, which reduces preparation time and reduces the welding level requirements of personnel. An electric drive lifting device is provided under the base of the dragging teaching collaborative robot, and the dragging teaching collaborative robot can match the welding height according to the position of the corner weld of the cable tower steel shell block.

[0059] Since the cross-section of the steel shell block is a large-angle diamond hexagonal cross-section, after assembly, the welding seams formed by the six inner wall panel units are first welded at intervals, and then the interval welds between the remaining inner wall panel units are welded; then the welds formed by the outer wall panel units are welded at intervals, and finally the interval welds between the remaining outer wall panel units are welded. The specific welding sequence is as follows: Fig.10 shown.

[0060] like Fig.15 , 16 As shown, during the automated welding of the steel shell wall panel's full penetration corner welds, the robot control program calls the automatic pulse CO2 gas shielded welding mode, and the gas shielded welding material uses flux-cored wire T554T1-1C1A-N3UH5 (φ1.2mm). The welding current is 170-190A, the arc voltage is 23-25V, the welding speed is 110-120mm / min, the dry extension is 12-18mm, the gas flow rate is 15-20L / min, the arc swing mode is an ascending triangle, the swing width is 6-8mm, the swing frequency is 40-45 times / min, and the left and right stops are both 0.7s.

[0061] like Fig. 9 As shown, the welding groove angle of the full penetration corner weld between the tower steel shell block wall panels is about 40°.

[0062] The vertical corner welds of the cable tower steel shell block are reserved within 200mm of the top to facilitate adjustment of the box mouth contour size during bridge installation. The welding is performed after the bridge position is precisely matched and positioned to ensure the matching accuracy of the cable tower steel shell block.

[0063] When the inner wall panel unit and the outer wall panel unit are subjected to standing penetration welding in step S7, in this embodiment, the corner welds of at least 15% of the length of the top are first welded, and in this embodiment, the corner welds within 1m are specifically welded, and then the remaining welds are welded from bottom to top, such as Fig.11 As shown, the top and bottom outline dimensions of the steel shell blocks of the double-layer dense grid stiffened wall panels are ensured.

[0064] By using the gantry RTE 496-S dual-arm robot welding system in combination with the consumable electrode gas shielded welding equipment to complete the automated welding work of the dense grid reinforcement of the wall panel unit, and using the FANUC CRX-5IA dragging teaching collaborative robot in combination with the consumable electrode gas shielded welding equipment to complete the automated welding work of the steel shell block's full penetration corner welds, combined with a specific welding sequence, the welding construction efficiency of the double-layer dense grid stiffened wall panel cable tower steel shell block is significantly improved, the production period is greatly shortened, and the welding quality stability and overall post-weld accuracy are more effectively guaranteed, which effectively promotes the application of automated welding technology in steel bridge manufacturing and accelerates the transformation of bridge construction technology to green and low-carbon.

[0065] In this embodiment, Figure 5 , 6 As shown, in step S3, at least 100 mm of non-weld area is reserved at both ends of the flat angle fillet welds between the vertical ribs, the transverse ribs and the steel wall panels, the end non-weld areas reserved between the vertical ribs and the steel wall panels are welded when the steel shell segments are pre-assembled, and the non-weld areas reserved between the transverse ribs and the steel wall panels are welded when the steel shell blocks are assembled, so as to ensure the matching accuracy between the vertical ribs and the transverse ribs.

[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automated welding method for a double-layer dense grid stiffening wall panel tower steel shell block, characterized in that: The following steps are involved: S1. Cutting and preparation of materials: steel wall panels, anchoring steel plates, vertical ribs and transverse ribs; S2. After assembling the vertical ribs, the transverse ribs and the anchoring steel plates on the steel wall panels in sequence to form a wall panel unit, the wall panel unit is fixed on the welding platform; S3. Program and input welding operations through online programming of the teaching pendant, including: S301, taking the weld in the center area of ​​the steel wall panel as the starting point, welding the vertical ribs one by one from the middle to both sides, and inputting the coordinate points of the vertical fillet welds between the vertical ribs and the transverse ribs into the welding system; S302, taking the weld in the center area of ​​the steel wall panel as the starting point, welding the vertical ribs one by one from the middle to both sides, and inputting the coordinate points of the flat angle fillet weld between the vertical rib and the steel wall panel into the welding system; S303, taking the weld in the center area of ​​the steel wall panel as the starting point, welding the transverse ribs one by one from the middle to both sides, and inputting the coordinate points of the flat angle fillet weld between the transverse rib and the steel wall panel into the welding system; S304, taking the short focus of the anchor steel plate as the starting point and performing symmetrical welding from the short focus to the long focus, inputting the coordinate points of the flat angle fillet weld between the anchor steel plate and the steel wall plate into the welding system; S4, automatically welding the wall panel units of the same size according to the data saved in step S3; S5. Weld shear studs at the center of the grid reinforcement formed by the transverse and vertical ribs; S6, cutting the peripheral margin of the wall panel unit and welding the groove, and tying the transverse ribs and vertical ribs to form a steel mesh; S7. Use the wall panel units to assemble in sequence to form inner wall panel units and outer wall panel units, assemble the supporting angle steel between the inner wall panel units and the outer wall panel units, and use the restraint tooling to weld the inner wall panel units and the outer wall panel units in sequence with standing penetration corner welds.

2. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 1 is characterized in that: The assembly of the wall panel unit in step S2 is specifically as follows: Place the steel siding flat on the flat frame, and use the vertical and horizontal baselines of the siding as the reference to mark the vertical and horizontal rib assembly position lines. Use the vertical rib assembly position lines as the reference to position and assemble the vertical ribs, and adjust and control the vertical rib position within an appropriate range; Use the assembly position line of the transverse rib as a reference to position and assemble the transverse rib, control the transverse rib to be in a suitable position, and check and control that the steel bar holes in the same row on the transverse rib and vertical rib correspond to a straight line; Using the center line of the steel wall panel anchor hole as a reference, position and assemble the anchor steel plate.

3. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 1 is characterized in that: The welding of the shear studs in step S5 is specifically as follows: First, the rigid constraint between the wall panel unit and the frame after the grid reinforcement welding is completed is released, the flatness of the wall panel unit is adjusted by heat correction, the wall panel unit is placed flat on the welding platform with the ribbed side facing up, the long side of the steel wall panel is ensured to be parallel to the walking direction of the welding machine, and the constraint tooling is used to rigidly fix it around the frame; Taking the weld in the center area of ​​the steel wall panel as the starting point, welding is carried out row by row from the middle to both sides, and the stud welding system is used to complete the welding of the shear studs in the grid formed by the transverse ribs and vertical ribs.

4. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 1 is characterized in that: Before step S3, when the vertical ribs, transverse ribs and anchoring steel plates are tack welded at a flat angle, the weld leg size of the tack weld is less than 3 mm, the length of the tack weld is 35-50 mm, and the spacing of the tack weld is 300-350 mm.

5. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 1 is characterized in that: In step S3, at least 100 mm of non-weld area is reserved at both ends of the flat-angle fillet welds between the vertical ribs, transverse ribs and steel wall panels. The end non-weld areas reserved between the vertical ribs and the steel wall panels are welded when the steel shell segments are pre-assembled, and the non-weld areas reserved between the transverse ribs and the steel wall panels are welded when the steel shell blocks are assembled.

6. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 1 is characterized in that: In step S7, the wall panel units are sequentially assembled to form inner wall panel units and outer wall panel units, and supporting angle steels are assembled between the inner wall panel units and the outer wall panel units, specifically: The qualified wall panel units are assembled in sequence to form inner wall panel units. The inner vertical panel units are placed on the segment assembly frame, and are positioned based on the ground sample line to control the top and bottom opening sizes of the inner wall panel units. After passing the inspection, they are fixed to the frame; The qualified wall panel units are assembled in sequence to form the outer wall panel units. The outer wall panel units are placed upright on the segment assembly frame. The outer wall panel units are positioned based on the ground sample line and the positioned inner wall panel units. The top and bottom sizes of the outer wall panel units and the spacing between the inner and outer wall panels are controlled. After the test is qualified, they are fixed with the frame and the inner wall panel. The supporting angle steels are assembled sequentially from top to bottom between the inner wall panel units and the outer wall panel units.

7. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 1 is characterized in that: In step S7, the inner wall panel unit and the outer wall panel unit are welded in sequence by using the restraint tooling, specifically: The inner and outer wall panel units are controlled by constraint tooling, and a single-sided welding and double-sided forming welding process is adopted. The vertical penetration corner welds between the wall panels of the inner wall panel unit are welded in sequence first, and then the vertical penetration corner welds between the wall panels of the outer wall panel unit are welded in sequence.

8. The automatic welding method for the double-layer dense grid stiffening wall panel tower steel shell block according to claim 7 is characterized in that: When the inner layer wall panel unit and the outer layer wall panel unit are subjected to standing penetration corner welding in step S7, the corner welds of at least 15% of the length of the top are welded first, and then the remaining welds are welded from bottom to top.

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