Precast pile welding machine and precast pile welding method

Abstract

This invention discloses a precast pile welding machine and a precast pile welding method. The support has a hollowed-out central area; a turntable structure is provided below the support, and the outer ring of the turntable structure can rotate circumferentially; a transverse drive mechanism is provided on the outer ring, and a turntable driven by a first motor is provided on the slide table of the transverse drive mechanism. The turntable is provided with a transmission component that can move along the Z-axis and Y-axis directions. The transmission component is provided with a mounting frame, and the mounting frame is provided with a welding torch for welding the weld seams of the precast pile and a scanning camera for scanning the weld seam trajectory of the precast pile. The precast pile welding machine does not need to be bound to the precast pile, and the welding of the precast pile gap is achieved by hoisting, which is convenient for adjustment; the use of a scanning camera to collect the weld seam trajectory can accurately obtain the coordinate position of the weld seam, realizing automatic welding processing of the weld seam at the connection position of the precast pile. After welding is completed, the welding image data is automatically uploaded to the background.

Description

Technical Field

[0001] This invention belongs to the field of pile foundation construction technology, and relates to a precast pile welding machine and a precast pile welding method. Background Technology

[0002] Currently, the construction method for welding precast piles (including pipe piles and square piles, with pipe piles having a circular cross-section and square piles having a square cross-section) is as follows: the lower section of the precast pile to be welded is driven into the soil, and then the upper section of the precast pile is suspended and aligned with the lower section, so that the end plates of the two piles are brought close together. A ring of welding is then performed around the joint of the end plates to make the upper and lower sections of the precast piles a whole, and then the pile is driven again. Then, the other upper section of the precast pile is hoisted into place and welded again. After the welding is completed, the pile is driven again, and this cycle is repeated until the entire pile driving task is completed.

[0003] Traditional precast pile welding relies on manual welding, which results in inconsistent welder skill levels and difficulty in guaranteeing weld quality. To address this, patent number CN106624514B proposes a pipe pile welding robot. This robot is fixed to the circumference of the pipe pile using three sets of support components, and a trolley welding platform on top performs the welding operation. However, because the entire pipe pile welding robot is fixed to the pipe pile, disassembly and assembly are inconvenient after one section is welded, preventing rapid transition to welding the next section.

[0004] Therefore, it is necessary to improve existing technologies to overcome their shortcomings. Summary of the Invention

[0005] The purpose of this invention is to provide a precast pile welding machine and a precast pile welding method, thereby overcoming the problems existing in the prior art through improvements to the precast pile welding equipment.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A precast pile welding machine includes a support for hoisting, the support having a hollowed-out central area; a turntable structure is provided below the support, the outer ring of the turntable structure being able to rotate circumferentially; a transverse drive mechanism is provided on the outer ring, a turntable driven by a first motor is provided on the slide of the transverse drive mechanism, the turntable is provided with a transmission component that can move along the Z-axis and Y-axis, the transmission component is provided with a mounting frame, the mounting frame is provided with a welding torch for welding the weld seam of the precast pile, and a scanning camera for scanning the weld seam trajectory of the pipe pile.

[0008] Furthermore, the mounting bracket is equipped with a recording camera for recording the weld seam.

[0009] Furthermore, the turntable structure includes an inner ring fixed to the bottom of the bracket, the inner circle of which corresponds to the middle area of ​​the bracket; an outer ring is nested around the inner ring and can rotate along the inner ring; a drive motor is provided on the bracket, a drive gear is provided on the drive shaft of the drive motor, and the outer surface of the outer ring is a circumferential gear that meshes with the drive gear.

[0010] Furthermore, the lateral drive mechanism is located below the circumferential gear; the lateral drive mechanism includes a lateral motor and a lateral lead screw module, and the housing of the lateral lead screw module is fixed on the outer ring.

[0011] Furthermore, the transmission assembly includes a vertical bracket fixedly connected to the slide of the transverse lead screw module. A vertical drive mechanism is mounted on the vertical bracket, comprising a vertical motor and a vertical lead screw module. The housing of the vertical lead screw module is fixed to the vertical bracket. A horizontal bracket is mounted on the slide of the vertical lead screw module, and a longitudinal drive mechanism is mounted on the horizontal bracket. The longitudinal drive mechanism comprises a longitudinal motor and a longitudinal lead screw module, and the housing of the longitudinal lead screw module is fixed to the horizontal bracket. The mounting bracket is disposed on the slide of the longitudinal lead screw module.

[0012] Furthermore, the stroke of the lateral drive mechanism should be greater than or equal to the inner diameter of the inner ring.

[0013] Furthermore, the precast pile welding machine is equipped with a laser rangefinder to determine the total length of the pile being pressed down (pile length). Specifically, the laser rangefinder is used to determine the downward movement distance of the clamp (the clamp is the component that holds the precast pile down). This laser rangefinder is also connected to a backend server, which processes the signals sensed by the laser rangefinder (counting downward movement of the precast pile, but not upward movement) to obtain the length of the pressed pile.

[0014] A method for welding precast piles includes the following steps:

[0015] Step 1: Initial state of the equipment. Then, the drive motor drives the outer ring to rotate 360°. During this process, the scanning camera scans the weld between the upper and lower precast piles, which are placed vertically.

[0016] Step 2: The backend server processes the scanned weld data by sampling points and obtains the horizontal distance La and vertical distance Ha between each sampling point and the scanning camera; it calculates the horizontal deviation position △L and vertical deviation position △H of each sampling point using the following formulas: △L = La - L; △H = Ha - H; where L is the distance from the scanning camera to the center point of the inner ring minus the radius of the pipe pile (or half the side length of the square pile); H is 0 in the initial state of the scanning camera.

[0017] Step 3: The backend server obtains the trajectory that the welding gun needs to move for each sampling point based on the horizontal deviation position △L and vertical deviation position △H of each sampling point, combined with the distance that the welding gun needs to penetrate under ideal conditions; and sends the movement command of the welding gun to the controller.

[0018] Step 4: The controller performs welding operations according to the type of precast pile. When the precast pile is a pipe pile, the lateral drive mechanism remains stationary. The welding machine starts, and the controller controls the vertical and longitudinal motors to bring the welding torch to the pipe pile. The drive motor drives the welding torch to rotate in a circle. The vertical and longitudinal motors adjust their positions according to the obtained sampling trajectory to complete the circumferential welding operation. When the precast pile is a square pile, the lateral motor drives the welding torch to the first position, the welding machine starts, and then controls the vertical and longitudinal motors to bring the welding torch to one end of the square pile. The lateral motor starts, and the vertical and longitudinal motors drive the welding torch according to the sampling trajectory. The welding torch performs welding operations on one side of the square pile until the weld on that side is completed. Then the welding torch returns to its original position, and the drive motor drives the welding torch to rotate by a specified angle. The welding torch performs welding operations on the other side of the square pile through the same steps, finally completing the welding operation of the square pile. The welding torch position does not need to be specially adjusted during welding (i.e., the scanning camera does not need to return to the initial position after scanning one revolution), and can be directly performed using the following two methods. The first method is to use the end point of the scanning camera as the starting point for welding with the welding torch. The second method is to have the backend server quickly process the scanning data during the scanning process, and the welding torch follows the scanning camera to perform welding during the scanning process (i.e., welding while scanning). Both methods can improve efficiency.

[0019] Furthermore, after welding is completed in step 4, the drive motor rotates the outer ring 360°. During this process, the recording camera captures and records the weld between the upper and lower precast pile sections and stores the data on the backend server. Each precast pile is numbered during pile driving, and its foundation data is also stored on the backend server. Therefore, the backend server enables the acquisition and storage of weld image data and the recording and storage of pile length.

[0020] Furthermore, the initial state of the device in step 1 refers to the following: the slide on the horizontal drive mechanism is in a specified position, the turntable is in a specified angle, the slide on the vertical drive mechanism is in a specified position, and the slide on the longitudinal drive mechanism is in a specified position; in this state, the distance from the scanning camera to the center point of the inner ring is a fixed value.

[0021] Furthermore, during the welding of the square pile in step 4, the first position corresponds to one end of the weld seam on the corresponding side, and the coordinates of this end are obtained by scanning with a scanning camera.

[0022] The above technical solution has the following advantages: the precast pile welding machine does not need to be bound to the precast pile, and the pipe pile gap welding is achieved by hoisting, which is convenient for adjustment; the scanning camera is used to collect the weld trajectory, which can accurately obtain the coordinate position of the weld and realize the automatic welding treatment of the weld at the connection position of the precast pile; the welding condition after welding is recorded, which is convenient for subsequent quality inspection and maintenance judgment. Attached Figure Description

[0023] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0024] The structures, proportions, sizes, etc. illustrated in this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0025] Figure 1 A schematic diagram of the assembled structure (pipe pile) provided by the present invention.

[0026] Figure 2 A schematic diagram of the assembled structure (square pile) provided by the present invention.

[0027] Figure 3 This is a three-dimensional schematic diagram provided for the present invention.

[0028] Figure 4 This is a bottom-view schematic diagram provided for the present invention.

[0029] Figure 5 This is a left-view schematic diagram provided for the present invention.

[0030] Figure 6 This is a front view schematic diagram provided for the present invention.

[0031] Figure 7 This is a schematic diagram of the process provided by the present invention.

[0032] Figure 8 This is a schematic diagram of the horizontal trajectory of the weld seam and welding torch under ideal conditions.

[0033] Figure 9 This is a schematic diagram of the horizontal trajectory of the weld seam and welding torch under actual conditions.

[0034] Figure 10 This is a schematic diagram of the vertical trajectory of the weld and welding torch under actual conditions. Detailed Implementation

[0035] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be noted that these descriptions are for the purpose of aiding understanding the present invention, but do not constitute a limitation thereof. Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0036] Example

[0037] See Figures 1-6 As shown, a precast pile welding machine includes a support 1 for hoisting. The central area of ​​the support 1 has a hollow structure to allow the precast pile to be vertically inserted and passed through. The upper end of the support 1 has four support points 101 for hoisting, and the lower end face of the support 1 has a circular turntable structure 2. The turntable structure 2 includes an inner ring 201, an outer ring 202, a drive motor 203, etc. The inner ring 201 is fixed on the support 1, and its inner ring corresponds vertically to the hollow structure of the support. The outer ring 202 is nested around the inner ring 201 and can rotate along the inner ring 201. The drive motor 203 is mounted on the support 1, and the drive shaft of the drive motor 203 is provided with a drive gear 204. The outer surface of the outer ring 202 is a circumferential gear that meshes with the drive gear 204, thereby enabling the drive motor 203 to drive the outer ring 202 to rotate circumferentially.

[0038] A transverse drive mechanism 3 (X-axis direction) is provided on the outer ring 202 below the circumferential gear. The transverse drive mechanism 3 is a transverse lead screw module 302 driven by a transverse motor 301. The housing of the transverse lead screw module 302 is fixed on the outer ring 202.

[0039] A turntable 10 driven by a first motor is mounted on the slide of the transverse lead screw module 302, and a transmission assembly is mounted on the turntable 10. This transmission assembly includes a vertical bracket 401 fixed to the slide of the transverse lead screw module 302, and a vertical drive mechanism 4 (Z-axis direction) mounted on the vertical bracket 401. The vertical drive mechanism 4 is a vertical lead screw module 403 driven by a vertical motor 402, and the housing of the vertical lead screw module 403 is fixed to the vertical bracket 401. A horizontal bracket 501 is mounted on the slide of the vertical lead screw module 403, located on one side of the vertical lead screw module 403 and moving up and down under the drive of the vertical motor 402. A longitudinal drive mechanism 5 (Y-axis direction) is mounted on the horizontal bracket 501, and the longitudinal drive mechanism 5 is a longitudinal lead screw module 503 driven by a longitudinal motor 502. The housing of the longitudinal lead screw module 503 is fixed to the horizontal bracket 501. A mounting bracket 6 is mounted on the slide of the longitudinal lead screw module 503.

[0040] The precast pile welding machine of this application has five-axis transmission functions, namely X-axis transmission provided by the transverse drive mechanism 3, Y-axis transmission provided by the longitudinal drive mechanism 5, Z-axis transmission provided by the vertical drive mechanism 4, circumferential rotation provided by the turntable structure 2, and circumferential offset rotation provided by the turntable 10.

[0041] The mounting frame 6 is equipped with a welding torch 7 for welding the weld seams of the precast piles. The mounting frame 6 also has a scanning camera 8 for scanning the weld seam trajectory of the precast piles. A recording camera 9 is also mounted on the mounting frame to photograph and record the weld seam after welding for later review. Each of the aforementioned transverse, vertical, and longitudinal lead screw modules has a corresponding cable chain to assist in stable operation.

[0042] The scanning camera 8 is constantly recording during the precast pile driving process and transmits the video data to the backend server. Because the signals from the cement column surface and the weld surface are different, the backend server can detect the weld and stop the precast pile driving operation. At this time, the weld is within the recognition area of ​​the scanning camera.

[0043] The precast pile welding machine of this invention is equipped with a laser rangefinder to determine the total length of the pile being pressed down (pile length). Specifically, the laser rangefinder is used to determine the downward movement distance of the clamp (the clamp is the component that holds the precast pile down). This laser rangefinder is also connected to a backend server, which processes the signals sensed by the laser rangefinder (counting downward movement of the precast pile, but not upward movement) to obtain the length of the pressed pile.

[0044] In this embodiment, the horizontal, vertical, and longitudinal lead screw modules were all purchased directly from the market and fall within the scope of existing technology; therefore, their specific structures will not be described further. The welding torch is connected to the welding machine via wiring. A control box is located outside the bracket 1. The controllers inside the control box are connected to the drive motor, horizontal motor, vertical motor, and longitudinal motor, respectively. The backend server is connected to the scanning camera, recording camera, and controller to realize automated welding operations of the equipment.

[0045] In this embodiment, the stroke of the lateral drive mechanism should be greater than or equal to the inner diameter of the inner ring to meet the welding requirements of square piles of different sizes.

[0046] like Figure 7 As shown, a precast pile welding method, using the aforementioned precast pile welding machine, includes the following steps:

[0047] Step 1: Initial equipment state. The drive motor rotates the outer ring 360°. During this process, the scanning camera scans the weld between the upper and lower precast pile sections, which are placed vertically. The initial equipment state means the slide on the horizontal drive mechanism is in a designated position, the turntable is at a designated angle, the slide on the vertical drive mechanism is in a designated position, and the slide on the longitudinal drive mechanism is in a designated position. In this state, the distance L1 from the scanning camera to the center point of the inner ring is a fixed value. Simultaneously, the welding torch remains stationary after installation, and the positional deviation between the scanning camera and the welding torch is also a fixed value. These fixed values ​​are measured and pre-stored in the background server.

[0048] like Figure 8 As shown, ideally, the precast pile is located in the exact center of the inner ring 201, and the welding torch can weld the precast pile by advancing a distance H1. Figure 8 In the diagram, S1 represents the weld trajectory of the precast pile, and S2 represents the movement trajectory of the welding torch. However, the actual situation is as follows... Figures 9-10 As shown, the precast pile is not located in the exact center of the inner ring 201. The horizontal and vertical distances (A1-A6) from the welding gun to the weld are different, so the position of the welding gun needs to be adjusted during welding.

[0049] Step 2: The backend server processes the scanned weld data by sampling points (1,000 points). The number of sampling points is adjusted in real time according to the length of the weld. The horizontal distance La and vertical distance Ha between each sampling point and the scanning camera are obtained. The horizontal deviation position ΔL and vertical deviation position ΔH of each sampling point are calculated using the following formulas: ΔL = La - L; ΔH = Ha - H; where L is the distance from the scanning camera to the center point of the inner ring minus the radius of the pipe pile (or half the side length of the square pile); H is 0 in the initial state of the scanning camera. In practical applications, L and H are fixed values ​​and do not change with the movement of the welding torch.

[0050] Step 3: The backend server obtains the trajectory (△L+H1, △H) that the welding gun needs to move at each sampling point based on the horizontal deviation position △L and vertical deviation position △H of each sampling point, combined with the distance H1 that the welding gun needs to penetrate under ideal conditions; and sends the movement command of the welding gun to the controller.

[0051] Step 4: The controller performs welding operations according to the type of precast pile. During welding, the welding torch does not need to return (i.e., the scanning camera does not need to return to its initial position after scanning once). The following two methods can be used: First: Use the end point of the scanning camera's scan as the starting point for welding; Second: During the scanning process, the background server quickly processes the scan data, and the welding torch follows the scanning camera during the scanning process (i.e., welding while scanning). Both methods can improve efficiency. Specifically:

[0052] When the precast pile is a pipe pile, the lateral drive mechanism is always stationary. When the welding machine is started, the controller controls the vertical motor and the longitudinal motor to make the welding torch touch the pipe pile. The drive motor drives the welding torch to rotate in a circle. The vertical motor and the longitudinal motor adjust their positions according to the obtained sampling trajectory, thereby completing the circumferential welding operation.

[0053] When the precast pile is a square pile, the horizontal motor drives the welding torch to the first position (the first position corresponds to one end of the weld seam on the corresponding side, and the coordinates of the end point are obtained by scanning with a scanning camera). The welding machine starts, and then the vertical motor and longitudinal motor are controlled to make the welding torch abut against one end of the square pile. The horizontal motor starts, and the vertical motor and longitudinal motor drive the welding torch according to the sampling trajectory. The welding torch performs welding operation on one side of the square pile until the welding of the weld seam on that side is completed. Then the welding torch returns to its original position, and the drive motor drives the welding torch to rotate by a specified angle (90° in this embodiment). The welding torch performs welding operation on the other side of the square pile through the same steps, and finally completes the welding operation of the square pile.

[0054] After welding is completed in steps 4 and 5, the drive motor rotates the outer ring 360°. During this process, the recording camera captures and records the weld between the upper and lower precast pile sections and stores the data on the backend server. Each precast pile is numbered during pile driving, and its foundation data is also stored on the backend server. Therefore, the backend server enables the acquisition and storage of weld image data and the recording and storage of pile length.

[0055] The working principle of this invention is as follows: Welding of precast pile seams is achieved through hoisting, eliminating the need for binding to the precast pile. Before welding, a scanning camera is used to capture the weld trajectory, obtaining precise weld coordinates. The system then calculates the horizontal and vertical movement distances required for each sampling point of the welding torch. A controller then moves the welding torch position according to the calculation results, thereby completing the welding operation. After welding, the welding process is photographed and recorded for subsequent quality inspection and maintenance.

[0056] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments. For those skilled in the art, various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and these variations still fall within the protection scope of the present invention.

Claims

1. A precast pile welding machine characterized by: The bracket for hoisting has a hollowed middle region; A turntable structure is arranged below the bracket, the turntable structure comprises an inner ring fixed at the bottom of the bracket and an outer ring nested outside the inner ring and capable of rotating circumferentially; the outer ring is provided with a horizontal driving mechanism for providing X-axis direction transmission, a sliding table on the horizontal driving mechanism is provided with a first motor driven turntable, the turntable is provided with a transmission assembly capable of moving along the Z-axis and Y-axis directions, the transmission assembly is provided with a mounting rack, the mounting rack is provided with a welding gun for welding at a weld of a prefabricated pile, a scanning camera for scanning a weld trajectory of the prefabricated pile, and a recording camera for recording the weld; The scanning camera is configured to scan the weld during 360° rotation of the outer ring driven by the driving motor, and a background server performs point sampling processing on the scanned weld data, calculates horizontal deviation position ΔL and vertical deviation position ΔH of each sampling point, wherein ΔL = La - L, ΔH = Ha - H, La is the horizontal distance between the sampling point weld and the scanning camera, Ha is the vertical distance, L is the distance from the scanning camera to the center point of the inner ring minus half of the radius of the pipe pile or the side length of the square pile, and H is the vertical distance in the initial state; the welding gun moves adaptively based on the trajectory data of ΔL and ΔH.

2. A precast pile welding machine according to claim 1, characterised in that: The recording camera records and photographs the weld after welding.

3. A precast pile welding machine according to claim 1, characterised in that: The driving motor of the turntable structure is engaged with a circumferential gear on the outside of the outer ring through a gear.

4. A precast pile welding machine according to claim 1, characterised in that: The horizontal driving mechanism is a horizontal screw module, and the stroke is greater than or equal to the inner diameter of the inner ring.

5. A method for welding a precast pile using the welding machine according to any one of claims 1 to 4, characterized in that The method comprises the following steps: Step 1: initial state of the equipment, then the driving motor drives the outer ring to rotate 360°, and the scanning camera scans the weld between the upper and lower prefabricated piles during the process, wherein the upper and lower prefabricated piles are placed in the vertical direction; wherein the initial state of the equipment is that the sliding table of the horizontal driving mechanism is at a specified position, the turntable is at a specified angle, the sliding table of the vertical driving mechanism is at a specified position, and the sliding table of the longitudinal driving mechanism is at a specified position; in this state, the distance from the scanning camera to the center point of the inner ring is a fixed value; Step 2: the background server performs point sampling processing on the scanned weld data, and obtains the horizontal distance La and the vertical distance Ha between each sampling point weld and the scanning camera; calculates the horizontal deviation position ΔL and the vertical deviation position ΔH of each sampling point, the calculation formula is as follows: ΔL = La - L; ΔH = Ha - H; wherein L is the distance from the scanning camera to the center point of the inner ring minus half of the radius of the pipe pile or the side length of the square pile; the scanning camera is in the initial state, and H is 0; Step 3: the background server obtains the trajectory of the welding gun that needs to move according to the horizontal deviation position ΔL and the vertical deviation position ΔH of each sampling point obtained, combined with the distance that the welding gun needs to penetrate in the ideal state, and sends the movement instruction of the welding gun to the controller. Step 4, the controller respectively performs welding operation according to the type of precast pile; when the precast pile is a pipe pile, the transverse driving mechanism is always in a stationary state, the welding machine is started, the controller controls the vertical motor and the longitudinal motor to make the welding gun abut on the pipe pile, the driving motor drives the welding gun to rotate circumferentially, the vertical motor and the longitudinal motor adjust the position according to the obtained sampling point trajectory, and then the circumferential welding operation is completed; when the precast pile is a square pile, the transverse motor drives the welding gun to be in a first position, the first position corresponds to an end point of a side weld, the coordinates of the end point are obtained by scanning the scanning camera, the welding machine is started, then the vertical motor and the longitudinal motor are controlled to make the welding gun abut on one end of the square pipe pile, the transverse motor is started, the vertical motor and the longitudinal motor drive the welding gun according to the sampling point trajectory, and the welding gun performs welding operation on one side weld of the square pile, until the welding of the side weld is completed; Then the welding gun is returned, the driving motor drives the welding gun to rotate by a specified angle, and the welding gun performs welding operation on the weld on the other side of the square pile through the same steps, and finally the welding of the weld of the square pile is completed. After the welding is completed, the driving motor drives the outer ring to rotate by 360 degrees, the recording camera records the weld between the upper precast pile and the lower precast pile in the process, and stores it in the background server.

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