A horizontal assembly system for I-shaped steel beams

Abstract

A horizontal assembly system for an I-beam steel beam includes a base, a supporting mechanism, a plurality of clamping mechanisms, a plurality of roller mechanisms, a plurality of vibration exciters, and a plurality of vibration pickups. The supporting mechanism is fixed to the upper end surface of the base, the clamping mechanism is arranged on the outer side of the supporting mechanism, the roller mechanism is installed between the supporting mechanism and the clamping mechanism, the vibration exciter is installed at the bottom of the panel, and the vibration pickup is installed at the top of the panel. The present invention realizes flexible docking of the I-beam steel beam at various angles through roller wheels, universal balls, multi-hole mounting plates and related mechanisms, thereby improving the efficiency and quality of the assembly and manufacturing of the I-beam steel beam. At the same time, the present invention can effectively detect the degree of deviation of the panel clamping point from the center line through the linkage of the vibration exciter and the vibration pickup, thereby achieving a high degree of coincidence between the center line of the panel and the side position of the web, and completing the high-precision assembly of the panel and the web, thereby producing high-quality I-beam steel beam products with good symmetry and positioning, and ensuring the safe use of bridge facilities.

Description

Technical Field

[0001] The invention belongs to the technical field of automation equipment, and in particular relates to a horizontal assembly system for I-shaped steel beams. Background Art

[0002] I-shaped bars are a typical component used in steel truss bridges and steel-concrete composite beam bridges. At present, about 35% of my country's bridge steel structures are I-shaped bars. Because their size, mechanical strength and other properties need to meet specified indicators, they need to be specially customized. In the construction of large bridges, I-shaped steel beams are often pre-assembled and welded, and then transported to the site for construction. However, the current I-shaped steel beam manufacturing process mostly uses fixed tire frames for assembly, which has the disadvantages of low versatility, low degree of automation, and difficult to control assembly accuracy. In addition, since the external dimensions of the I-shaped steel beams required for bridge construction are very large, the assembly and manufacturing efficiency of the I-shaped steel beams is low and the dimensional control accuracy is low. Therefore, the prior art requires a new type of equipment for realizing high-precision and high-efficiency I-shaped steel beam assembly operations. Summary of the invention

[0003] In view of the above-mentioned deficiencies in the prior art, the present invention provides a horizontal assembly system for I-shaped steel beams, which is used to realize high-quality automated assembly operations for I-shaped steel beams.

[0004] The technical solution of the present invention is as follows: A horizontal assembly system of an I-beam steel beam, including a base, a supporting mechanism, a plurality of clamping mechanisms, and a plurality of roller mechanisms. The base is a welded component and is placed on the ground or a platform; the supporting mechanism includes a plurality of supporting platforms, a plurality of universal roller mechanisms, and a connecting rod. The plurality of supporting platforms are column-shaped welded components and are fixed to the upper end surface of the base on the left and right sides. The universal roller mechanism is installed above each supporting platform, and a connecting rod is installed between the supporting platforms on the left and right sides; the plurality of clamping mechanisms are arranged on the outside of the supporting mechanism on the left and right sides. The clamping mechanism includes a clamping column, a clamping cylinder, and a multi-hole mounting plate. The clamping column is fixed on the base, the clamping cylinder body is fixed on the clamping column, and the multi-hole mounting plate is fixed on the clamping column toward the supporting mechanism. The side wall of one side of the structure; the roller mechanism includes a roller base, two bearing seats, and a roller wheel, wherein two of the bearing seats are fixed to the upper end surface of the roller base, and the roller wheel is installed in the middle in a shaft-hole matching manner, and multiple roller mechanisms are arranged on both sides of the upper area of ​​the base in the same number and installed in the gap between the supporting mechanism and the clamping mechanism; a plurality of universal roller mechanisms can be placed on transversely arranged webs, and a plurality of roller mechanisms can be placed on vertically arranged panels. By adjusting the height of the roller mechanism and applying pressure to the middle by the clamping cylinders on both sides, the middle sections of the panels on both sides can be pressed against the central transversely arranged web, so as to implement welding and assembly operations.

[0005] Furthermore, the present invention also includes a plurality of servo electric cylinders, which are modular products integrating a servo motor and a lead screw, and are arranged in equal numbers on the left and right parts of the base, with the cylinder body fixed on the base, and the output shaft facing upward and connected to the roller base.

[0006] Furthermore, the present invention also includes multiple exciters and multiple vibration pickups. The exciters have the function of generating mechanical vibrations and are installed at the bottom of the multiple vertically arranged panels. The vibration pickups have the function of sensing vibration signals and converting them into electrical signals and are installed at the tops of the multiple panels. When the panel is simultaneously pressed against the output shaft of the clamping cylinder on one side and the side edge of the web on the other side, the pressed position forms a clamping position. The bottom exciter is turned on to cause the panel to generate horizontal mechanical vibrations. The mechanical waves are transmitted to the vibration pickup at the top of the panel through the clamping point. If the lengths of the upper and lower parts of the panel separated by the clamping position are inconsistent, the vibration amount will be amplified or reduced through the lever principle, thereby causing the amplitude of the mechanical wave transmitted to the upper end of the panel to be amplified or reduced. The horizontal height of the roller mechanism is adjusted according to the amplitude difference detected by the vibration pickup until the amplitude difference at both ends of the panel is close to a certain range, thereby ensuring the precise alignment of the middle of the panel and the side edge of the web.

[0007] Furthermore, a support plate, a telescopic sleeve, a contact head and a spring are provided on the output shaft of the squeezing cylinder. An inner hole is provided in the middle of the support plate, and the telescopic sleeve is installed in a sleeve-fitting manner. One end of the telescopic sleeve is pressed against the output shaft of the squeezing cylinder through the spring, and the other end is provided with the contact head.

[0008] Furthermore, the sides of the porous mounting plate and the roller base are provided with a plurality of through holes of equal size distributed in an equidistant array.

[0009] Furthermore, the axis of the output shaft of the squeezing oil cylinder is parallel to the upper end surface of the universal roller mechanism, and the distance between the two in the vertical direction is maintained to be less than 150 mm.

[0010] Furthermore, a universal ball is provided on the top of the universal roller mechanism.

[0011] Furthermore, when the detection amplitude of the vibration pickup is between 0.95 and 1.05 times the excitation amplitude of the vibration exciter, the vertical adjustment of the roller mechanism is stopped and the clamping cylinders on both sides are started to completely clamp the web and the panels on both sides thereof, thereby implementing the welding operation.

[0012] Furthermore, the vibration frequency of the mechanical wave generated by the exciter is in the range of 2-3000 Hz.

[0013] Furthermore, the exciter is connected to the pulse power supply in a circuit, and the vibration pickup is connected to the calculation module in a circuit. Both the exciter and the vibration pickup realize the conversion between the electrical signal and the mechanical vibration signal through the electrostrictive or magnetostrictive material.

[0014] Furthermore, the contact head is arc-shaped on one side facing the supporting mechanism.

[0015] The beneficial effects of the present invention are:

[0016] 1. The present invention realizes flexible docking of I-beams at various angles through roller wheels, universal balls and related mechanisms, and utilizes the displacement adjustment function of a porous mounting plate and a servo electric cylinder, and can implement integrated operations of lifting, assembling, welding and unloading of raw material panels and webs, thereby being able to meet the assembly and production operations of various I-beams in China, greatly improving the efficiency and quality of I-beam assembly and manufacturing, and having the advantages of low cost, high efficiency, strong versatility, easy operation and high degree of automation.

[0017] 2. The present invention utilizes a principle similar to that of a lever-type vibrometer. Through the linkage between the vibrator and the vibration pickup, the degree to which the clamping point of the panel deviates from the center line can be effectively detected. When the clamping point deviates toward one side of the vibrator, the panel is equivalent to a labor-intensive lever and amplifies the amplitude of the mechanical wave transmitted to the vibration pickup. When the clamping point deviates toward one side of the vibration pickup, the panel is equivalent to a labor-saving lever and reduces the amplitude of the mechanical wave transmitted to the vibration pickup. Only when the detection amplitude of the vibration pickup is very close to the excitation amplitude of the vibrator can the clamping point ensure accurate positioning with the center line of the panel, thereby clamping the two side cylinders and implementing assembly welding, achieving a high degree of coincidence between the center line of the panel and the side edge of the web, completing high-precision assembly of the panel and the web, thereby producing high-quality I-beam steel beam products with good symmetry and positioning, ensuring the safe use of bridge facilities, and having good social benefits and practical value.

[0018] 3. The present invention adjusts the height position of the roller mechanism by connecting the porous mounting plate with the through holes of the roller base and assembling with bolt pairs. The height of the roller mechanism can be precisely fine-tuned by the high precision of the servo electric cylinder, thereby satisfying the production of products of various specifications. When batch production of ordinary products is implemented, the height of the roller mechanism is fixed by the porous mounting plate and the bolt pairs for mass production and assembly. When high-specification bridge products need to be produced, accurate positioning can be achieved by the servo electric cylinder, thereby improving the adaptability of steel beam assembly equipment to the production of various products. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the assembly structure of the present invention;

[0020] Figure 2 It is a structural schematic diagram of the squeezing oil cylinder in the present invention;

[0021] Figure 3 It is a structural schematic diagram of the roller mechanism in the present invention;

[0022] Figure 4 It is a schematic diagram of the assembly state of the face plate and the web in the present invention;

[0023] Figure 5 is a schematic diagram of the calibration operation of the present invention;

[0024] Figure 6 It is a schematic diagram of clamping and assembling of the present invention.

[0025] In the figure: 1-base, 11-panel, 12-web, 2-support mechanism, 21-support platform, 22-universal roller mechanism, 23-connecting rod, 3-clamping mechanism, 31-clamping column, 32-clamping cylinder, 32a-aft plate, 32b-telescopic sleeve, 32c-contact head, 32d-spring, 33-multi-hole mounting plate, 4-roller mechanism, 41-roller base, 42-bearing seat, 43-roller wheel, 5-servo electric cylinder, 6-vibrator, 7-vibrator pickup. DETAILED DESCRIPTION

[0026] The invention will be further described in detail below in conjunction with the accompanying drawings and embodiments.

[0027] like Figure 1-3As shown, a horizontal assembly system of an I-beam steel beam includes a base 1, a supporting mechanism 2, a plurality of clamping mechanisms 3, a plurality of roller mechanisms 4, and a plurality of servo electric cylinders 5. The base 1 is a welded component and is placed on the ground or a platform; the supporting mechanism 2 includes a plurality of supporting platforms 21, a plurality of universal roller mechanisms 22, and a connecting rod 23. The plurality of supporting platforms 21 are columnar welded components and are fixed to the upper end surface of the base 1 on the left and right sides. The universal roller mechanism 22 is installed above each supporting platform 21. A universal ball is provided on the top of the universal roller mechanism 22. A connecting rod 23 is installed between the supporting platforms 21 on the left and right sides; the plurality of clamping mechanisms 3 are arranged on the outside of the supporting mechanism 2 on the left and right sides. The clamping mechanism 3 includes a clamping column 31, a clamping cylinder 32, a multi-hole installation The mounting plate 33, wherein the squeezing column 31 is fixed on the base 1, the squeezing oil cylinder 32 is fixed on the squeezing column 31, and the output shaft thereof is provided with a butt plate 32a, a telescopic sleeve 32b, a contact head 32c, and a spring 32d. The middle part of the butt plate 32a is provided with an inner hole, and the telescopic sleeve 32b is sleeved and installed. One end of the telescopic sleeve 32b is pressed against the output shaft of the squeezing oil cylinder 32 through the spring 32d, and the other end thereof is provided with the contact head 32c. The contact head 32c is arc-shaped toward one side of the supporting mechanism 2. At the same time, the axis of the output shaft of the squeezing oil cylinder 32 is parallel to the upper end surface of the universal roller mechanism 22. And keep the distance between the two in the vertical direction less than 150mm; the porous mounting plate 33 is fixed on the side wall of the squeeze column 31 facing the support mechanism 2; the roller mechanism 4 includes a roller base 41, two bearing seats 42, and a roller wheel 43, wherein two of the bearing seats 42 are fixed to the upper end surface of the roller base 41, and the roller wheel 43 is installed in the middle in the form of shaft hole matching. Multiple roller mechanisms 4 are arranged on both sides of the upper area of ​​the base 1 in the same number and installed in the gap between the support mechanism 2 and the squeeze mechanism 3; the sides of the porous mounting plate 33 and the roller base 41 are provided with multiple equidistant arrays Through holes of equal size and distributed in rows; a plurality of the universal roller mechanisms 22 can be placed on a transversely arranged web 12, and a plurality of the roller mechanisms 4 can be placed on a vertically arranged panel 11. By adjusting the height of the roller mechanisms 4 and applying pressure to the middle by the squeezing cylinders 32 on both sides, the middle sections of the panels 11 on both sides can be pressed against the central transversely arranged web 12, so as to implement welding and assembly operations; the servo electric cylinder 5 is a modular product integrating a servo motor and a lead screw, and is arranged in the same number on the left and right parts of the base 1, with its cylinder body fixed on the base 1, and its output shaft facing upward and connected to the roller base 41.

[0028] like Figure 4As shown, the present invention also includes a plurality of exciters 6 and a plurality of vibration pickups 7, wherein the exciters 6 have the function of generating 2-3000Hz mechanical waves and are connected to the pulse power supply by forming a circuit; the vibration pickup 7 has the function of sensing vibration signals and converting them into electrical signals and is connected to the computing module by forming a circuit; the exciters 6 and the vibration pickups 7 both realize the conversion between electrical signals and mechanical vibration signals through electrostrictive materials; when the two panels 11 are respectively placed vertically on the roller mechanisms 4 on the left and right sides and one web 12 is placed horizontally above the two universal roller mechanisms 11, the two exciters 6 are respectively installed on the side edges of the two side panels 11 near the bottom, and then the two vibration pickups 7 are respectively installed on the side edges of the two side panels 12 near the top.

[0029] The working steps of the present invention are as follows:

[0030] Step 1: If Figure 5 As shown, two panels 11 of different lengths are placed on the roller mechanisms 4 on the left and right sides respectively through a sling, and then one of the webs 12 is placed horizontally above the two universal roller mechanisms 11. When the web 12 is not in the correct position, since it is supported by the universal ball on the universal roller mechanism 11, the web 12 can be forced to slide by hitting it with a hammer until its position is corrected to a qualified standard; when it is necessary to mass-produce steel beams with lower specifications, the center line of the panel 11 is directly measured and marked manually, the servo electric cylinder 5 is started to adjust the horizontal height of the roller mechanism 4 and visually align it with the side of the web 12 and then stop, and the servo electric cylinder 5 is fine-tuned to ensure that the multi-hole mounting plate 33 is aligned with the through hole of the roller base 41, and then the bolt pair is installed thereon to fix it, and the squeezing cylinders 32 on both sides are started to clamp and weld the two side panels 11 and the middle web 12, so as to ensure that the position of the roller mechanism 4 is fixed and repeated operations are performed to realize conventional steel beam mass production operations.

[0031] Step 2: When it is necessary to produce an I-shaped steel beam with higher specifications, it is necessary to maintain a good position and symmetry, so there is no need to install the bolt pair on the porous mounting plate 11; Figure 5 As shown, at this time, the left panel 11 is in a relatively high position, and the right panel 11 is in a relatively low position. At this time, the clamping cylinders 32 on both sides are started to make their output shafts press against the two panels 11. At the same time, the output force is controlled to ensure that the panel 11 only contacts the contact head 32c on the clamping cylinder 32, and does not contact the abutment plate 32a.

[0032] Step 3: Turn on the two vibrators 6 to generate horizontal mechanical vibrations with a frequency of 60 Hz at the bottom of the panels 11 that are in contact with each other. Since the panel 11 is simultaneously abutted by the contact head 32c on one side and the side edge of the web 12 on the other side, a clamping position is formed at the abutting position. The clamping position of the left panel 11 is lower than the center line, and the clamping position of the right panel 11 is higher than the center line. When the mechanical wave generated by the vibrator 6 is transmitted at the bottom, the left panel 11 is regarded as a laborious lever, which increases the amplitude of the mechanical wave transmitted to the top of the left panel 11. Similarly, the transmission of the mechanical wave regards the right panel 12 as a labor-saving lever. The amplitude of the mechanical wave transmitted to the top of the right panel 11 is reduced; at this time, the servo electric cylinder 5 is fine-tuned to make the panel 11 suspended in the air under the action of the clamping force, and then fully vibrates under the clamping of the arc-shaped contact head 32c; the mechanical wave is transmitted to the vibration pickup 7 at the top of the panel 11 after passing through the clamping position, and the amplitude difference between the feedback mechanical wave at the top of the panel 11 and the excitation mechanical wave 7 at the bottom is detected by the two vibration pickups 7. Through the calculation module connected thereto, a start instruction is sent to the servo electric cylinders 5 on both sides according to the size of the amplitude difference feedback signal, so that the output shaft of the left servo electric cylinder 5 decreases and the output shaft of the right servo electric cylinder 5 increases (such as Figure 5 At this time, fine-tune the squeezing cylinder 32 to facilitate sliding of the panel. When the horizontal height of the roller mechanism 4 is adjusted to the calculated distance, stop the servo electric cylinder 5 and restart the squeezing cylinder 32 to clamp the panel 11 in the air. Turn on the exciter 6 and the vibration pickup 7 again and repeat the operation until the amplitudes at both ends of the panel 11 are very close, and ensure that the detection amplitude of the vibration pickup 7 is 0.95 to 1.05 times the excitation amplitude of the exciter 6. Then stop the fine-tuning operation of the roller mechanism 4 to complete the precise alignment of the center lines of the left and right panels 11 and the sides of the middle web 12.

[0033] Step 4: When the center line of the panel 11 and the side of the web 12 are precisely aligned, restart the two-side squeeze cylinder 32 to make the abutment plate 32a completely abut against the side of the panel 11, and ensure that the spring 32d on the output shaft is compressed and the telescopic sleeve 32b and the contact head 32c are inserted into the inner hole of the abutment plate 32a, so that the abutment plate 32a on the two-side squeeze cylinder 32 is completely against the panel 11, and a clamping force is formed on the middle two panels 11 and a web 12 (such as Figure 6 As shown by the arrow, since the position of the panel 11 has been accurately adjusted, welding and assembly operations are carried out in this state to produce a high-specification I-beam product with excellent symmetry and position.

[0034] The above description is only a preferred embodiment of the present invention and does not constitute a formal limitation on the present invention. For those skilled in the art, various equivalent substitutions made by utilizing the features of the claims of the present invention should all fall within the protection scope of the present invention.

Claims

1. A horizontal assembly system for an I-shaped steel beam, comprising a base, a supporting mechanism, a plurality of squeezing mechanisms, and a plurality of roller mechanisms, characterized in that: The base is a welded component and is placed on the ground or a platform. The supporting mechanism includes a plurality of supporting platforms, a plurality of universal roller mechanisms, and a connecting rod. The plurality of supporting platforms are column-shaped welded components and are fixed to the upper end surface of the base on the left and right sides. The universal roller mechanism is installed above each supporting platform, and a connecting rod is installed between the supporting platforms on the left and right sides. The plurality of clamping mechanisms are arranged on the outside of the supporting mechanism on the left and right sides. The clamping mechanism includes a clamping column, a clamping cylinder, and a multi-hole mounting plate. The clamping column is fixed on the base, the cylinder body of the clamping cylinder is fixed on the clamping column, and the multi-hole mounting plate is fixed on the clamping column toward the supporting mechanism. The roller mechanism comprises a roller base, two bearing seats, and roller wheels, wherein two of the bearing seats are fixed to the upper end surface of the roller base, and the roller wheels are installed in the middle thereof in a shaft-hole matching manner. A plurality of roller mechanisms are arranged on both sides of the upper area of ​​the base in the same number, and are installed in the gap between the supporting mechanism and the clamping mechanism. A plurality of universal roller mechanisms can be placed on the transversely arranged webs, and a plurality of roller mechanisms can be placed on the vertically arranged panels. By adjusting the height of the roller mechanism and applying pressure to the middle by the clamping cylinders on both sides, the middle sections of the panels on both sides can be pressed against the transversely arranged webs in the center, so as to implement welding and assembly operations; It also includes a plurality of vibration exciters and a plurality of vibration pickups. The vibration exciters have the function of generating mechanical vibrations and are installed at the bottom of the plurality of vertically arranged panels. The vibration pickups have the function of sensing vibration signals and converting them into electrical signals and are installed at the tops of the plurality of panels. When the panel is simultaneously pressed against the output shaft of the clamping cylinder on one side and the side edge of the web on the other side, the pressed position forms a clamping position. The bottom vibration exciter is turned on to generate horizontal mechanical vibrations in the panel to which it is attached. The mechanical waves are transmitted to the vibration pickup at the top of the panel through the clamping point. If the lengths of the upper and lower parts of the panel separated by the clamping position are inconsistent, the vibration amount will be amplified or reduced through the principle of leverage, thereby causing the amplitude of the mechanical wave transmitted to the upper end of the panel to be amplified or reduced. The horizontal height of the roller mechanism is adjusted according to the amplitude difference detected by the vibration pickup until the amplitude difference at both ends of the panel is close to a certain range, thereby ensuring the precise alignment of the middle of the panel and the side edge of the web for assembly. The output shaft of the squeezing cylinder is provided with a support plate, a telescopic sleeve, a contact head and a spring. An inner hole is provided in the middle of the support plate, and the telescopic sleeve is installed in a sleeve-fitted manner. One end of the telescopic sleeve is pressed against the output shaft of the squeezing cylinder through the spring, and the other end is provided with the contact head, which is arc-shaped toward the side of the supporting mechanism.

2. The I-beam horizontal assembly system according to claim 1, further comprising a plurality of servo electric cylinders, characterized in that: The servo electric cylinder is a modular product integrating a servo motor and a lead screw, and is arranged in the same number on the left and right parts of the base, with the cylinder body fixed on the base, and the output shaft facing upward and connected to the roller base.

3. The I-beam horizontal assembly system according to claim 1, characterized in that: The sides of the porous mounting plate and the roller base are both provided with a plurality of through holes of equal size and distributed in an equidistant array.

4. The I-beam horizontal assembly system according to claim 1, characterized in that: The axis of the output shaft of the squeezing oil cylinder is parallel to the upper end surface of the universal roller mechanism, and the distance between the two in the vertical direction is maintained less than 150mm.

5. The I-beam horizontal assembly system according to claim 1, characterized in that: A universal ball is arranged on the top of the universal roller mechanism.

6. The I-beam horizontal assembly system according to claim 1, characterized in that: When the detection amplitude of the vibration pickup is between 0.95 and 1.05 times the excitation amplitude of the vibration exciter, the vertical adjustment of the roller mechanism is stopped and the clamping cylinders on both sides are started to completely clamp the web and the panels on both sides thereof, thereby performing welding operations.

7. The I-beam horizontal assembly system according to claim 1, characterized in that: The vibration frequency of the mechanical wave generated by the exciter is in the range of 2-3000 Hz.

8. The I-beam horizontal assembly system according to claim 1, characterized in that: The exciter is connected to the pulse power supply in a circuit, and the vibration pickup is connected to the calculation module in a circuit. Both the exciter and the vibration pickup realize the conversion between the electrical signal and the mechanical vibration signal through the electrostrictive or magnetostrictive material.

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