A U-rib welding device and welding process for steel structure bridge

Abstract

The present invention discloses a U-rib welding device and process for steel bridges. The device comprises a welding system and a pretreatment system, wherein the U-rib is welded using the welding system. The pretreatment system comprises an internal treatment system and an external treatment system. The internal treatment system comprises a movable carriage, a base, and a first loading mechanism. The base is a hollow structure fixed to the base of the movable carriage. The first loading mechanisms are symmetrically arranged on the left and right sides of the base, and the inner groove of the U-rib is loaded by the first loading mechanism. The external treatment system comprises a movable gantry structure and a second loading mechanism. The second loading mechanism is used to load the outer weld seam of the U-rib. The present invention utilizes full penetration welding and pretreatment processes to improve the overall quality of steel bridge decks.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge processing, and more particularly to a U-rib welding device for steel structure bridges. Background Art

[0002] U-rib reinforcement is a common reinforcement method for steel bridge decks. With the increasing incidence of U-rib bridge deck defects, the requirements for welding U-rib structures to existing bridge decks are constantly increasing. Previously, U-rib welding required 80% penetration on a single side, resulting in poor weld quality on the steel bridge deck and the tendency for cracks to form after commissioning. Summary of the Invention

[0003] The purpose of the present invention is to provide a U-rib welding device and welding process for a steel structure bridge, which adopts full penetration welding and pretreatment processes to improve the overall quality of the steel bridge deck.

[0004] The technical solution adopted by the present invention to solve this technical problem is: a U-rib welding device for a steel structure bridge, comprising: a welding system and a pretreatment system, wherein the U-rib is welded by the welding system; the pretreatment system comprises an internal treatment system and an external treatment system;

[0005] The internal processing system includes a mobile trolley, a base body and a first feeding mechanism; the base body is a hollow structure fixed to the base of the mobile trolley, and the first feeding mechanism is symmetrically arranged on the left and right sides of the base body, and the inner groove of the U rib is fed by the first feeding mechanism;

[0006] The external processing system includes a movable gantry structure and a second loading mechanism; the second loading mechanism is used to load the outer weld of the U rib.

[0007] Preferably, the first feeding mechanism comprises: a feeding body and a positioning mechanism;

[0008] The feeding body includes a feed head and a feed transition section. The cross section of the feed head matches the shape of the inner groove of the U-rib. The feed head is a hollow structure, and discharge holes are arranged in an array on the upper and lower surfaces. Smoothing bristles are provided on the upper and lower sides of the feed head along the depth direction of the inner groove. The feed head is detachably connected to the feed transition section, and the feed transition section is a hollow structure.

[0009] The positioning mechanism includes a first hydraulic rod and a connecting slider, the first hydraulic rod is hinged to the lower end of the base body, the other end of the first hydraulic rod is hinged to the feed transition section, the connecting slider is slidably arranged on a first slide rail vertically installed on the base body, the feed transition section is hinged to the connecting slider, and a slot is provided on one side of the base body adjacent to the first slide rail;

[0010] A material storage mechanism is provided in the base body, which includes a material box, a first flexible feed pipe, a second feed pipe and a pump. The material box is fixed in the base body, and the second feed pipes are symmetrically installed on both sides of the material box. The pump is installed on the second feed pipe, and the second feed pipe is connected to the first flexible feed pipe. The first flexible feed pipe passes through the slot and is connected to the feed transition section.

[0011] Preferably, the movable gantry structure includes: a second slide rail, a gantry, a bottom bracket and an inclination adjustment assembly; a pair of second slide rails are arranged on both sides of the panel and extend along the length direction of the U rib, the gantry is slidably arranged on the second slide rails, and the inclination adjustment assembly is composed of a plurality of second hydraulic rods, and the second hydraulic rods are connected to the bottom bracket in groups of two, the upper end of the second hydraulic rod is connected to the gantry, and the lower end of the bottom bracket is symmetrically provided with a third hydraulic rod, and the third hydraulic rod is connected to the second feeding mechanism.

[0012] Preferably, the second feeding mechanism includes a feeding body and a second positioning mechanism;

[0013] The second adjustment mechanism includes a fourth hydraulic rod and a second material box; the second material box is connected to the third hydraulic rod, the feeding transition section of the second feeding mechanism is hinged to the second material box, one end of the fourth hydraulic rod is hinged to the second material box, and the other end of the fourth hydraulic rod is hinged to the feeding transition section of the second feeding mechanism, and the second material box is connected to the feeding transition section of the second feeding mechanism through a pipeline and a pump.

[0014] The present invention also provides a welding process using the U-rib welding device for steel structure bridges, comprising the following steps:

[0015] S1: The groove processing device performs groove processing on the U rib to form the inner groove of the U rib;

[0016] S2: Assemble the U-rib and panel, with the assembly gap required to be less than 0.5mm. After assembly and positioning, apply the pretreatment composition to the inner and outer welds simultaneously, with the coating thickness controlled at 0.5-1.5mm;

[0017] S3: Use a DC welding machine to perform automatic submerged arc welding on the inner and outer sides of the U rib simultaneously. The inner welding current is 350-400A, the outer welding current is 600-650A, the inner welding wire diameter is 1.2mm, and the outer welding wire diameter is 3.2mm.

[0018] Preferably, the slope of the inner groove of the U-rib is 40° to 45°, the thickness of the U-rib is 7-9 mm, and the thickness of the panel is 14-18 mm.

[0019] Preferably, the step S2 specifically includes:

[0020] S21: Loading the internal processing system and the external processing system loading body in advance through the pump;

[0021] S22: The first feeding mechanism of the internal processing system is adjusted to be opposite to the inner groove of the U-rib, and the second feeding mechanism of the external processing system is adjusted to be opposite to the outer weld of the U-rib, ensuring that the distance between the feeding head of the first feeding mechanism and the inner groove and the distance between the feeding head of the second feeding mechanism and the weld are slightly larger than the coating thickness, and ensuring that the distance between the smoothing brush bristles and the inner groove / the distance between the welds are equal to the coating thickness;

[0022] S23: Start the mobile trolley and each pump to complete the loading of the treatment composition.

[0023] Preferably, the pretreatment composition is prepared by mixing 5-10 parts by weight of cerium carbonate, 45-55 parts by weight of urea resin, and 40-60 parts by weight of solvent ethanolamine.

[0024] The present invention includes at least the following beneficial effects: when submerged arc welding is used, the cerium carbonate in the pretreatment composition instantly decomposes to generate CeO2 and carbon dioxide after reaching a high temperature during calcination, and the urea resin and ethanolamine also decompose into carbon dioxide under high temperature conditions. The CeO2 that is finally retained in the weld area can improve the metal stability of the weld area, improve the internal structure inside the weld, and improve the toughness of the weld. The carbon dioxide decomposed at high temperature ensures that the weld area is not in contact with the air, avoids weld porosity defects, and improves the overall strength of the weld. The tensile strength of the specimen and the impact energy of the weld center are greatly improved, and the weld surface quality is good.

[0025] Other advantages, objectives and features of the present invention will be reflected in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the U-rib welding device for steel structure bridges of the present invention;

[0027] Figure 2 It is a schematic diagram of the processing system of the present invention;

[0028] Figure 3 It is a schematic diagram of the material head of the present invention;

[0029] Figure 4 It is a schematic diagram of the external processing system of the present invention.

[0030] Explanation of the accompanying drawings: 1 moving trolley, 2 base body, 3U rib, 4 panel, 5 material head, 6 feed transition section, 7 smoothing brush, 8 second slide rail, 9 door frame, 10 bottom bracket, 11 second hydraulic rod, 12 third hydraulic rod, 13 second feeding mechanism, 14 discharge hole, 15 connecting slider, 16 first hydraulic rod, 17 first flexible feed pipe, 18 material box, 19 second feed pipe, 20 pump, 21 fourth hydraulic rod, 22 material box two. DETAILED DESCRIPTION

[0031] The present invention is described in detail and completely below in conjunction with the embodiments. Those skilled in the art will be able to implement the present invention based on these descriptions. Before describing the present invention in conjunction with the embodiments, it should be noted that the technical solutions and technical features provided in various parts of the present invention, including the following description, may be combined with each other unless they conflict.

[0032] It should be noted that the experimental methods described in the following embodiments are conventional methods unless otherwise specified, and the reagents and materials can be obtained from commercial channels unless otherwise specified.

[0033] In addition, the embodiments of the present invention described below are generally only part of the embodiments of the present invention, rather than all of the embodiments. Therefore, based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making any creative efforts should fall within the scope of protection of the present invention.

[0034] like Figures 1 to 4 As shown, a U-rib welding device for a steel structure bridge includes: a welding system and a pretreatment system, wherein the U-rib 3 is welded by the welding system; the pretreatment system includes an internal treatment system and an external treatment system;

[0035] The internal processing system includes a mobile trolley 1, a base 2 and a first feeding mechanism; the base 2 is a hollow structure fixed to the base of the mobile trolley 1, and the first feeding mechanism is symmetrically arranged on the left and right sides of the base 2, and the inner groove of the U rib 3 is fed by the first feeding mechanism;

[0036] The external processing system includes a movable gantry structure and a second loading mechanism 13 ; the second loading mechanism 13 is used to load the outer weld of the U rib 3 .

[0037] In another technical solution, the first feeding mechanism includes: a feeding body and a positioning mechanism;

[0038] The feeding body includes a feed head 5 and a feed transition section 6. The cross section of the feed head 5 matches the shape of the inner groove of the U-rib 3. The feed head 5 can be replaced according to the shape of the inner groove. The feed head 5 is a hollow structure, and discharge holes 14 are arranged in an array on the upper and lower surfaces. Smoothing bristles 7 are provided on the upper and lower sides of the feed head 5 along the depth direction of the inner groove. The feed head 5 is detachably connected to the feed transition section 6, and the feed transition section 6 is a hollow structure.

[0039] The positioning mechanism includes a first hydraulic rod 16 and a connecting slider 15. The first hydraulic rod 16 is hinged to the lower end of the base body 2, and the other end of the first hydraulic rod 16 is hinged to the feed transition section 6. The connecting slider 15 is slidably set on a first slide rail vertically installed on the base body 2. The feed transition section 6 is hinged to the connecting slider 15. The inclination angle of the feeding body is adjusted by the first hydraulic rod 16. A slot is provided on one side of the base body 2 adjacent to the first slide rail for the first flexible feed pipe 17 to pass through the slot. When the connecting slider 15 moves up and down, the first flexible feed pipe 17 can move together;

[0040] A material storage mechanism is provided in the base body 2, which includes a material box 18, a first flexible feed pipe 17, a second feed pipe 19 and a pump 20. The material box 18 is fixed in the base body 2, and the second feed pipes 19 are symmetrically installed on both sides of the material box 18. The pump 20 is installed on the second feed pipe 19. The second feed pipe 19 is connected to the first flexible feed pipe 17, and the first flexible feed pipe 17 passes through the slot and is connected to the feed transition section 6.

[0041] In another technical solution, the movable gantry 9 structure includes: a second slide rail 8, a gantry 9, a bottom bracket 10 and an inclination adjustment assembly; a pair of second slide rails 8 are arranged on both sides of the panel 4 and extend along the length direction of the U rib 3, and the gantry 9 is slidably arranged on the second slide rail 8, and the inclination adjustment assembly is composed of a plurality of second hydraulic rods 11, and the second hydraulic rods 11 are connected to the bottom bracket 10 in groups of two, and the upper end of the second hydraulic rod 11 is connected to the gantry 9, and the lower end of the bottom bracket 10 is symmetrically provided with a third hydraulic rod 12, and the third hydraulic rod 12 is connected to the second feeding mechanism 13, and the third hydraulic rod 12 drives the second feeding mechanism 13 to move up and down and adjust the position, and the second feeding mechanism 13 in groups of two performs feeding at the outer weld of the U rib 3.

[0042] In another technical solution, the second feeding mechanism 13 includes a feeding body, which has the same structure as the feeding body of the first feeding mechanism, and a second positioning mechanism;

[0043] The second positioning mechanism includes a fourth hydraulic rod 21 and a second material box 22; the second material box 22 is connected to the third hydraulic rod 12, the feeding transition section 6 of the second feeding mechanism 13 is hinged to the second material box 22, one end of the fourth hydraulic rod 21 is hinged to the second material box 22, and the other end of the fourth hydraulic rod 21 is hinged to the feeding transition section 6 of the second feeding mechanism 13, and the second material box 22 is connected to the feeding transition section 6 of the second feeding mechanism 13 through a pipeline and a pump 20.

[0044] The present invention also provides a welding process using the U-rib 3 welding device for steel structure bridges, comprising the following steps:

[0045] S1: The groove processing device performs groove processing on the U rib 3 to form an inner groove of the U rib 3;

[0046] S2: Assemble the U-rib 3 and the panel 4. The assembly gap is required to be less than 0.5 mm. After assembly and positioning, apply the pretreatment composition to the inner and outer welds at the same time. The coating thickness is controlled at 0.5 to 1.5 mm.

[0047] S3: A DC welding machine is used to perform synchronous automatic submerged arc welding on the inner and outer sides of the U rib 3. The inner welding current is 350-400A, and the outer welding current is 600-650A. The inner welding wire is CHW-55CNH with a diameter of 1.2mm, and the outer welding wire is H10Mn2 with a diameter of 3.2mm.

[0048] In another technical solution, the slope of the inner groove of the U-rib 3 is 40° to 45°, the thickness of the U-rib 3 is 7-9 mm, and the thickness of the panel 4 is 14-18 mm.

[0049] In another technical solution, the step S2 is specifically as follows:

[0050] S21: Loading the internal processing system and the external processing system loading body in advance through the pump 20;

[0051] S22: The first feeding mechanism of the internal processing system is adjusted to be opposite to the inner groove of the U-rib 3, and the second feeding mechanism 13 of the external processing system is adjusted to be opposite to the outer weld of the U-rib 3, ensuring that the distance between the feed head 5 of the first feeding mechanism and the inner groove, and the distance between the feed head 5 of the second feeding mechanism 13 and the weld are slightly larger than the coating thickness, and ensuring that the distance between the smoothing brush bristles 7 and the inner groove / the distance between the weld are equal to the coating thickness;

[0052] S23: Start the mobile trolley 1 and each pump 20 to complete the loading of the treatment composition.

[0053] In another technical solution, the pretreatment composition is prepared by mixing 5-10 parts of cerium carbonate, 45-55 parts of urea resin, and 40-60 parts of solvent ethanolamine, in weight fractions.

[0054] Example 1

[0055] The welding process of the U-rib welding device for steel structure bridges, wherein the U-rib thickness is 8 mm and the panel thickness is 16 mm, includes the following steps:

[0056] S1: The groove processing device performs groove processing on the U-rib to form an inner groove of the U-rib, and the slope of the inner groove of the U-rib is 40°;

[0057] S2: Assemble the U-rib and panel, with the assembly gap required to be less than 0.5mm. After assembly and positioning, apply the pretreatment composition to the inner and outer welds at the same time, with the coating thickness controlled at 0.6mm;

[0058] S3: Use a DC electric welding machine to perform automatic submerged arc welding on the inner and outer sides of the U rib simultaneously. The inner welding current is 360A, the outer welding current is 620A, the inner welding wire is CHW-55CNH with a diameter of 1.2mm, and the flux is SJ-101. The outer welding wire is H10Mn2 with a diameter of 3.2mm and the flux is SJ-101.

[0059] Comparative Example 1 has the same welding process as Example 1, except that the U ribs in Comparative Example 1 do not have grooves. The disadvantage is that the qualified rate is lower and other properties are slightly reduced.

[0060] Comparative Example 2 has the same welding process as Example 1, except that the pretreatment composition is not added in Comparative Example 2S2.

[0061] Comparative Example 3

[0062] The welding process of the U-rib welding device for steel structure bridges, wherein the U-rib thickness is 8 mm and the panel thickness is 16 mm, includes the following steps:

[0063] S1: The groove processing device performs groove processing on the U-rib to form an inner groove of the U-rib, and the slope of the inner groove of the U-rib is 40°;

[0064] S2: Assemble the U-rib and panel, and the assembly gap must be less than 0.5mm;

[0065] S3: A DC electric welding machine is used to perform synchronous automatic submerged arc welding on the inner and outer sides of the U rib. The inner welding current is 360A, the outer welding current is 620A, the inner welding wire is CHW-55CNH welding wire with a diameter of 1.2mm, the flux is SJ-101, and the outer welding wire is H10Mn2 welding wire with a diameter of 3.2mm. The flux for the inner and outer welding is a mixture of SJ-101 and an equal amount of the pretreatment composition of Example 1.

[0066] Mechanical tests and phased array ultrasonic testing were performed on the weld seams of the specimens of Example 1 and Comparative Examples 1 to 3. The results are shown in Table 1.

[0067] Table 1

[0068]

[0069]

[0070] As can be seen from Table 1, the U-rib specimen is pre-coated at the welding position with a pretreatment composition. When submerged arc welding is used, the cerium carbonate in the pretreatment composition instantly decomposes into CeO2 and carbon dioxide after reaching a high temperature during calcination, and the urea resin and ethanolamine also decompose into carbon dioxide under high temperature conditions. The CeO2 that is finally retained in the weld area can improve the metal stability of the weld area, improve the internal structure inside the weld, and improve the weld toughness. The carbon dioxide decomposed at high temperature ensures that the weld area is not in contact with air, avoids weld porosity defects, and improves the overall strength of the weld. The tensile strength of the specimen and the impact energy of the weld center are greatly improved.

[0071] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the description and implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. A U-rib welding device for steel structure bridges, characterized in that: include: Welding system and pretreatment system, the U rib is welded by the welding system; the pretreatment system includes an internal treatment system and an external treatment system; The internal processing system includes a mobile trolley, a base body and a first feeding mechanism; the base body is a hollow structure fixed to the base of the mobile trolley, and the first feeding mechanism is symmetrically arranged on the left and right sides of the base body, and the inner groove of the U rib is fed by the first feeding mechanism; The external processing system includes a movable gantry structure and a second loading mechanism; The second feeding mechanism is used to feed the outer weld of the U rib; The first feeding mechanism includes: a feeding body and a positioning mechanism; The feeding body includes a feed head and a feed transition section. The cross section of the feed head matches the shape of the inner groove of the U-rib. The feed head is a hollow structure, and discharge holes are arranged in an array on the upper and lower surfaces. Smoothing bristles are provided on the upper and lower sides of the feed head along the depth direction of the inner groove. The feed head is detachably connected to the feed transition section, and the feed transition section is a hollow structure. The positioning mechanism includes a first hydraulic rod and a connecting slider, the first hydraulic rod is hinged to the lower end of the base body, the other end of the first hydraulic rod is hinged to the feed transition section, the connecting slider is slidably arranged on a first slide rail vertically installed on the base body, the feed transition section is hinged to the connecting slider, and a slot is provided on one side of the base body adjacent to the first slide rail; A material storage mechanism is provided in the base body, which includes a material box, a first flexible feed pipe, a second feed pipe and a pump. The material box is fixed in the base body, and the second feed pipes are symmetrically installed on both sides of the material box. The pump is installed on the second feed pipe, and the second feed pipe is connected to the first flexible feed pipe. The first flexible feed pipe passes through the slot and is connected to the feed transition section.

2. The U-rib welding device for steel structure bridge according to claim 1, characterized in that: The movable gantry structure includes: a second slide rail, a gantry, a bottom bracket and an inclination adjustment assembly; a pair of second slide rails are arranged on both sides of the panel and extend along the length direction of the U rib, the gantry is slidably arranged on the second slide rail, and the inclination adjustment assembly is composed of a plurality of second hydraulic rods, and the second hydraulic rods are connected to the bottom bracket in groups of two, the upper end of the second hydraulic rod is connected to the gantry, and the lower end of the bottom bracket is symmetrically provided with a third hydraulic rod, and the third hydraulic rod is connected to the second feeding mechanism.

3. The U-rib welding device for steel structure bridge according to claim 2, characterized in that: The second feeding mechanism includes a feeding body and a second positioning mechanism; The second adjustment mechanism includes a fourth hydraulic rod and a second material box; the second material box is connected to the third hydraulic rod, the feeding transition section of the second feeding mechanism is hinged to the second material box, one end of the fourth hydraulic rod is hinged to the second material box, and the other end of the fourth hydraulic rod is hinged to the feeding transition section of the second feeding mechanism, and the second material box is connected to the feeding transition section of the second feeding mechanism through a pipeline and a pump.

4. A welding process using the U-rib welding device for steel structure bridges according to any one of claims 1 to 3, characterized in that: The following steps are involved: S1: The groove processing device performs groove processing on the U rib to form the inner groove of the U rib; S2: Assemble the U-rib and panel, with the assembly gap required to be less than 0.5mm. After assembly and positioning, apply the pretreatment composition to the inner and outer welds simultaneously, with the coating thickness controlled at 0.5~1.5mm; S3: Use a DC electric welding machine to perform automatic submerged arc welding on the inner and outer sides of the U rib simultaneously. The inner welding current is 350~400A, the outer welding current is 600~650A, the inner welding wire diameter is 1.2mm, and the outer welding wire diameter is 3.2mm.

5. The welding process of the U-rib welding device for steel structure bridge according to claim 4, characterized in that: The slope of the inner groove of the U rib is 40°~45°, the thickness of the U rib is 7-9mm, and the thickness of the panel is 14-18mm.

6. The welding process of the U-rib welding device for steel structure bridge according to claim 4, characterized in that: The specific steps in step S2 are: S21: Loading the internal processing system and the external processing system loading body in advance through the pump; S22: The first feeding mechanism of the internal processing system is adjusted to be opposite to the inner groove of the U-rib, and the second feeding mechanism of the external processing system is adjusted to be opposite to the outer weld of the U-rib, ensuring that the distance between the feeding head of the first feeding mechanism and the inner groove and the distance between the feeding head of the second feeding mechanism and the weld are slightly larger than the coating thickness, and ensuring that the distance between the smoothing brush bristles and the inner groove / the distance between the welds are equal to the coating thickness; S23: Start the mobile trolley and each pump to complete the loading of the treatment composition.

7. The welding process of the U-rib welding device for steel structure bridge according to claim 4, characterized in that: The pretreatment composition is prepared by mixing 5-10 parts of cerium carbonate, 45-55 parts of urea resin and 40-60 parts of solvent ethanolamine in weight fractions.

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