Automatic high-strength bolt screwing device for steel box girder and construction method thereof

Abstract

The application discloses a kind of high-strength bolt automatic screwing device for steel box girder and its construction method, comprising: support beam, both ends are formed with wheel frame, wheel frame is equipped with electric roller and can be lifted and installed with locking seat, locking seat is installed with electromagnetic component;Moving seat is connected to sliding block, and moving seat is slidably provided with lifting column;Pier is translatably installed at the lower end of lifting column, and electric wrench is movably arranged on the pier, the rotating main shaft of electric wrench is connected with screwing head, and electric pusher is installed on the pier;Torque sensor is installed on rotating main shaft;Camera and distance sensor are installed on the pier;Controller is connected to electric roller, electromagnetic component, first driving structure, second driving structure, linear module, electric pusher, electric wrench, torque sensor, camera and distance sensor.The application solves the problem that the existing automatic bolt screwing device cannot detect the torque of the bolt, which easily leads to the deformation or damage of the bolt thread.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to an automatic bolt tightening device for steel box girders and its construction method. Background Technology

[0002] Steel box girders have been increasingly widely used in the construction of various large-scale bridges in my country since the 1980s due to their advantages such as high torsional resistance, ease of installation, light weight, and novel structure. However, to date, the high-strength bolt connection between the transverse diaphragms and web plates of steel box girder bridges still mainly relies on manual labor during construction, which easily leads to the following problems:

[0003] 1. Poor working conditions and high risk of manual labor. During the tightening of high-strength bolts, workers often have to rely on simple suspended platforms or nets for high-altitude work, which leads to significant safety hazards.

[0004] 2. High labor intensity and low tightening efficiency. For a highway steel box girder bridge section with a length and width of about 40m, the number of high-strength bolts used to connect the cross diaphragms alone is as high as nearly 10,000. Coupled with working at height, the labor intensity is extremely high. Moreover, every time the installation position is moved, the workers have to reposition the suspended platform, which also makes the manual tightening efficiency low.

[0005] 3. Manual tightening has poor stability, and the consistency and reliability of tightening high-strength bolts cannot be effectively guaranteed, which directly affects the overall construction quality of steel box girder bridges;

[0006] 4. Torque measurement and data acquisition are difficult to implement. Currently, it is difficult to implement accurate torque control, monitor torque data changes, and retest the final tightening torque data during the tightening of high-strength bolts, and it is impossible to achieve full coverage of all bolt inspections.

[0007] Currently, some design patents for automatic bolt tightening devices have been reported, but these tightening devices still have certain problems in terms of operating conditions, structural design, working methods, installation and maintenance, for example:

[0008] Chinese patent CN109317959A discloses an automatic bolt tightening device and method for steel arch frame assembly. The automatic tightening mechanism of this device is relatively simple in design, operating only in one direction. Manual alignment of the device with the work point is still required, and after tightening at one point, manual repositioning is necessary. While this reduces the intensity of manual labor, labor costs remain high. Furthermore, the device's tightening design cannot detect bolt torque, making it prone to over-tightening during operation, leading to thread deformation or damage and unreliable connections. Therefore, this automatic bolt tightening device cannot meet the bolt tightening conditions and process requirements for steel box girder assembly. Summary of the Invention

[0009] To overcome the shortcomings of existing technologies, an automatic bolt tightening device and its construction method for high-strength bolts used in steel box girders are provided to solve the problem that existing automatic bolt tightening devices cannot detect the torque of bolts, which can easily lead to bolt thread deformation or damage.

[0010] To achieve the above objectives, an automatic tightening device for high-strength bolts used in steel box girders is provided, comprising:

[0011] A support beam has wheel frames at both ends, each wheel frame is equipped with an electric roller, and a locking seat is mounted on the wheel frame in a height-adjustable manner. An electromagnetic component is mounted on the locking seat. When the locking seat is lowered and the electromagnetic component is energized, the electromagnetic component magnetically attracts the steel box beam to lock the support beam. The support beam has a sliding groove arranged along the length of the support beam, and a slider is slidably arranged in the sliding groove.

[0012] A movable seat is connected to the slider. A first driving structure for driving the slider is installed on the movable seat. The movable seat has a vertical through hole. A hanging column is slidably disposed in the vertical through hole. A second driving structure for driving the hanging column to rise and fall is installed on the movable seat.

[0013] The support platform is slidably installed at the lower end of the hanging column via a linear module. The support platform is equipped with a guide rail, and a slider is slidably mounted on the guide rail. An electric wrench is mounted on the slider, and a tightening bit is connected to the rotating spindle of the electric wrench. A reaction plate is formed on the support platform, and an electric jacking component for pushing the electric wrench is mounted on the reaction plate.

[0014] A torque sensor for acquiring the torque of the rotating spindle is installed on the rotating spindle;

[0015] A camera for capturing images of multiple bolts to be tightened on the transverse diaphragm of the steel box girder is installed on the bearing platform;

[0016] A distance sensor for collecting the real-time distance between the platform and the diaphragm is installed on the platform;

[0017] A controller, installed on the support beam, is connected to the electric roller, the electromagnetic component, the first drive structure, the second drive structure, the linear module, the electric jacking component, the electric wrench, the torque sensor, the camera, and the distance sensor. The controller acquires the real-time distance. When the real-time distance meets a preset distance value, the controller acquires the image and identifies the bolt to be tightened on the crossbeam. After identifying the bolt, the controller controls the first drive structure, the second drive structure, and the linear module to coordinate and move the support platform so that the tightening bit is aligned with the bolt. After the tightening bit is aligned with the bolt, the controller controls the electric jacking component to engage the tightening bit with the bolt. After the tightening bit is engaged with the bolt, the controller controls the electric wrench to rotate the tightening bit and acquire the torque. When the torque reaches a preset torque, the controller shuts off the electric wrench.

[0018] Furthermore, the electric rollers are rotatably mounted on opposite ends of the wheel frame, and the locking seat is disposed between the two electric rollers.

[0019] Furthermore, the locking seat is vertically and flexibly mounted on the middle of the wheel frame via a cylinder.

[0020] Furthermore, the controller is located at one end of the support beam, and an automatic take-up device is installed at the other end of the support beam.

[0021] Furthermore, there are multiple distance sensors, which are arranged along the circumferential direction of the electric wrench.

[0022] Furthermore, the distance sensor is a laser distance sensor.

[0023] Furthermore, the electric jacking component is an electro-hydraulic push rod.

[0024] Furthermore, the first driving structure includes:

[0025] A rack is installed on the groove wall of the slide;

[0026] A gear is rotatably mounted on the slider and meshes with the rack;

[0027] A transverse motor is driven by the gear and mounted on the movable base.

[0028] This invention provides a construction method for an automatic bolt tightening device for steel box girders, comprising the following steps:

[0029] The controller controls the electric rollers so that the screwdriver bit on the support beam is aligned with the bridge diaphragm to be constructed.

[0030] The distance sensor collects the real-time distance between the abutment and the diaphragm of the bridge;

[0031] The controller acquires the real-time distance. When the real-time distance meets the preset distance value, the controller activates the locking seat and the electromagnetic component. The electromagnetic component is attracted to the steel box girder to lock the supporting beam.

[0032] After locking the support beam, the controller acquires the image and identifies the bolts to be tightened on the diaphragm;

[0033] After identifying the bolt to be tightened, the controller controls the first drive structure, the second drive structure, and the linear module to move the support platform in coordination so that the tightening bit is aligned with the bolt to be tightened;

[0034] After the tightening bit is aligned with the bolt to be tightened, the controller controls the electric pusher to make the tightening bit fit onto the bolt to be tightened;

[0035] After the screwdriver bit is fitted onto the bolt to be tightened, the controller controls the electric wrench to rotate the screwdriver bit and obtain the torque. When the torque reaches the preset torque, the controller turns off the electric wrench.

[0036] The beneficial effects of this invention are as follows: The automatic high-strength bolt tightening device for steel box girders comprises a walking mechanism consisting of electric rollers, wheel frames, and support beams, enabling rapid movement or position changes at different tightening stations on the steel box girder, effectively reducing the safety risks and labor intensity of manual tightening. After the device moves into position, the electromagnetic component on the locking seat magnetically attracts the steel box girder to lock the device, effectively ensuring the overall stability of the device during the tightening process. This invention, through its moving seat and hanging column structure, enables the bearing platform to perform high-strength bolt tightening operations on diaphragms of different lengths, greatly improving the device's versatility and reducing worker labor intensity and safety risks. This invention achieves precise control of the bolt tightening movement process by driving the electric wrench with an electric jacking component. This invention achieves accurate positioning of the bolt tightening operation by setting up a camera and distance sensor and using machine vision methods to calibrate the coordinates of all bolt holes on the diaphragms of the steel box girder. This invention achieves precise control and measurement feedback of torque during the bolt tightening process through a torque sensor. Attached Figure Description

[0037] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0038] Figure 1 This is a schematic diagram of the automatic tightening device for high-strength bolts used in steel box girders according to an embodiment of the present invention.

[0039] Figure 2 This is a schematic diagram of the structure of the foundation according to an embodiment of the present invention. Detailed Implementation

[0040] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0041] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0042] Reference Figure 1 and Figure 2 As shown, the present invention provides an automatic bolt tightening device for high-strength bolts for steel box girders, comprising: a support beam 1, a movable seat 2, a bearing platform 3, a torque sensor 4, a camera 5, a distance sensor 6, and a controller 7.

[0043] Wheel frames 11 are formed at both ends of the support beam 1. Electric rollers 12 are mounted on the wheel frames 11. Locking seats 13 are mounted on the wheel frames 11 in a height-adjustable manner. Electromagnetic components are mounted on the locking seats 13. When the locking seats 13 descend and the electromagnetic components are energized, the electromagnetic components magnetically attract the steel box girder to lock the support beam 1. The support beam 1 has a sliding groove arranged along its length. A slider slides within the sliding groove.

[0044] The movable base 2 is connected to the slider. A first drive structure for driving the slider is mounted on the movable base 2. The movable base 2 has a vertical through hole. A hanging column 31 is slidably mounted in the vertical through hole. A second drive structure for driving the hanging column 31 to rise and fall is mounted on the movable base 2.

[0045] The support platform 3 is slidably mounted on the lower end of the hanging column 31 via a linear module 38. A guide rail 32 is mounted on the support platform 3. A slider 33 is slidably mounted on the guide rail 32. An electric wrench 34 is mounted on the slider 33, and a tightening bit 37 is connected to the rotating spindle of the electric wrench 34. A reaction plate 36 is formed on the support platform 3. An electric jacking component 35 for jacking the electric wrench 34 is mounted on the reaction plate 36.

[0046] Torque sensor 4 is mounted on the rotating spindle. Torque sensor 4 is used to collect the torque of the rotating spindle.

[0047] Camera 5 is mounted on the pier cap 3. Camera 5 is used to capture images of multiple bolts to be tightened on the transverse diaphragms of the steel box girder.

[0048] Distance sensor 6 is mounted on the foundation 3. It is used to collect the real-time distance between the foundation 3 and the transverse diaphragm.

[0049] Controller 7 is mounted on support beam 1. Controller 7 is connected to electric roller 12, electromagnetic components, first drive structure, second drive structure, linear module 38, electric jacking component 35, electric wrench 34, torque sensor 4, camera 5, and distance sensor 6. Controller 7 acquires real-time distance. When the real-time distance matches a preset distance value, controller 7 acquires an image and identifies the bolt to be tightened on the crossbeam. After identifying the bolt, controller 7 controls the first drive structure, second drive structure, and linear module 38 to coordinate the movement of support platform 3 so that tightening bit 37 is aligned with the bolt. After tightening bit 37 is aligned with the bolt, controller 7 controls electric jacking component 35 to engage tightening bit 37 with the bolt. After tightening bit 37 is engaged with the bolt, controller 7 controls electric wrench 34 to rotate tightening bit 37 and acquire torque. When the torque reaches a preset torque, controller 7 shuts off electric wrench 34.

[0050] The controller 7 is located at one end of the support beam 1. An automatic take-up device is installed at the other end of the support beam 1.

[0051] In this embodiment, the support beam is approximately 5.2m long, with a rectangular cross-section and a thickness of approximately 6mm. Double lifting lugs are welded to the top surface of the support beam for hoisting. A slider is installed on one side of the support beam, a groove is provided on another side, and an electrical control cabinet is installed on the third side. Controllers with touch-screen displays and cable reels are mounted at both ends of the support beam. This invention, by incorporating an automatic cable reel (or automatic winding device), avoids cable tangling that could affect construction during the dragging and retrieval of long-distance power transmission lines.

[0052] In this embodiment, electric rollers 12 are rotatably mounted at opposite ends of the wheel frame 11. A locking seat 13 is disposed between the two electric rollers 12.

[0053] In a preferred embodiment, the locking seat 13 is vertically mounted to the center of the wheel frame 11 via a cylinder. The controller is connected to the cylinder.

[0054] In this embodiment, there are multiple distance sensors 6. The multiple distance sensors 6 are arranged along the circumferential direction of the electric wrench 34.

[0055] As a preferred embodiment, the distance sensor 6 is a laser distance sensor 6.

[0056] When the real-time distance values ​​collected by all distance sensors match the preset distance values, the controller activates the cylinder and the electromagnetic component, causing the locking seat to descend and the electromagnetic component to generate magnetism. The magnetism of the electromagnetic component attracts the steel box girder, thus locking the entire device.

[0057] In this embodiment, the electric roller is a solid wheel with a diameter of approximately 40–50 mm.

[0058] The locking seat installed on the inside of the wheel frame can provide a suction force of about 1T via an electromagnetic component.

[0059] In a preferred embodiment, the first drive structure includes a rack, a gear, and a transverse motor 21. The rack is mounted on the wall of the slide groove. The gear is rotatably mounted on the slider and meshes with the rack. The transverse motor is driven by the gear and mounted on the movable base 2.

[0060] In this embodiment, the groove wall of the slide has a receiving groove. The receiving groove is used to receive the rack. Alternatively, a through groove is formed on the side of the movable seat facing the support beam, and the rack is received in the through groove.

[0061] In this embodiment, the second drive structure is the same as the first drive structure. Specifically, the second drive structure includes a rack, a gear, and a lifting motor 22. The rack is mounted on the side of the lifting column and is arranged along the axial direction of the lifting column. The gear is rotatably mounted on a movable base. The lifting motor is driven by the gear and mounted on the movable base.

[0062] The lifting support moves laterally along the support beam under the drive of the lateral movement motor, with a maximum lateral travel of approximately 4.5m. The lifting column moves vertically under the drive of the lifting motor, with a maximum vertical travel of approximately 1.6m. A linear module and a support platform are installed at the lower end of the lifting column, with the linear module bolted to the lifting column via a connecting plate. Both the lifting column and the linear module are made of high-strength aluminum profiles, ensuring high rigidity while reducing the overall weight of the tightening device to achieve high precision control. The support platform moves along the linear module slide via a linear module motor, with a maximum travel of approximately 500mm.

[0063] The slider can move linearly along the guide rail, with a maximum travel of approximately 50mm. A torque sensor is mounted on the top of the electric wrench's rotating spindle, and the torque sensor is threadedly connected to the tightening bit.

[0064] A camera and a laser distance sensor are installed on the platform.

[0065] In a preferred embodiment, the electric jacking component 35 is an electro-hydraulic push rod. The electric jacking component is arranged along the length of the guide rail 32.

[0066] This invention provides a construction method for an automatic bolt tightening device for steel box girders, comprising the following steps:

[0067] S1, Controller 7 controls the electric roller 12 so that the screwdriver bit 37 on the support beam 1 is aligned with the bridge diaphragm to be constructed.

[0068] S2, Distance sensor 6 collects the real-time distance between the abutment 3 and the bridge diaphragm.

[0069] S3, Controller 7 obtains the real-time distance. When the real-time distance meets the preset distance value, Controller 7 activates the locking seat 13 and the electromagnetic component. The electromagnetic component is attracted to the steel box girder to lock the supporting beam 1.

[0070] S4. After locking the support beam 1, the controller 7 acquires an image and identifies the bolts to be tightened on the diaphragm.

[0071] S5. After identifying the bolt to be tightened, the controller 7 controls the first drive structure, the second drive structure, and the linear module 38 to work together to move the support platform 3 so that the tightening bit 37 is aligned with the bolt to be tightened.

[0072] S6. After the tightening bit 37 is aligned with the bolt to be tightened, the controller 7 controls the electric pusher 35 to make the tightening bit 37 fit onto the bolt to be tightened.

[0073] S7. After the tightening bit 37 is fitted onto the bolt to be tightened, the controller 7 controls the electric wrench 34 to rotate the tightening bit 37 and obtain torque. When the torque reaches the preset torque, the controller 7 turns off the electric wrench 34.

[0074] The automatic high-strength bolt tightening device for steel box girders of this invention comprises a traveling mechanism consisting of electric rollers, a wheel frame, and a support beam, enabling rapid movement or repositioning at different tightening stations on the steel box girder, effectively reducing the safety risks and labor intensity of manual tightening. After the device moves into position, the electromagnetic component on the locking seat magnetically attracts the steel box girder to lock the device, effectively ensuring the overall stability of the device during the tightening process. This invention, through its moving seat and hanging column structure, enables the tightening of high-strength bolts on diaphragms of varying lengths, greatly improving the device's versatility and reducing worker labor intensity and safety risks. This invention achieves precise control of the bolt tightening movement process by driving the electric wrench with an electric jacking component. This invention achieves accurate positioning of the bolt tightening operation by using a camera and distance sensor, employing machine vision methods to calibrate the coordinates of all bolt holes on the diaphragms of the steel box girder. This invention, through a torque sensor, achieves precise control and measurement feedback of the torque during bolt tightening.

[0075] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. An automatic tightening device for high-strength bolts used in steel box girders, characterized in that, include: A support beam has wheel frames at both ends, each wheel frame is equipped with an electric roller, and a locking seat is mounted on the wheel frame in a height-adjustable manner. An electromagnetic component is mounted on the locking seat. When the locking seat is lowered and the electromagnetic component is energized, the electromagnetic component magnetically attracts the steel box beam to lock the support beam. The support beam has a sliding groove arranged along the length of the support beam, and a slider is slidably arranged in the sliding groove. A movable seat is connected to the slider. A first driving structure for driving the slider is installed on the movable seat. The movable seat has a vertical through hole. A hanging column is slidably disposed in the vertical through hole. A second driving structure for driving the hanging column to rise and fall is installed on the movable seat. The support platform is slidably installed at the lower end of the hanging column via a linear module. The support platform is equipped with a guide rail, and a slider is slidably mounted on the guide rail. An electric wrench is mounted on the slider, and a tightening bit is connected to the rotating spindle of the electric wrench. A reaction plate is formed on the support platform, and an electric jacking component for pushing the electric wrench is mounted on the reaction plate. A torque sensor for acquiring the torque of the rotating spindle is installed on the rotating spindle; A camera for capturing images of multiple bolts to be tightened on the transverse diaphragm of the steel box girder is installed on the bearing platform; A distance sensor for collecting the real-time distance between the platform and the diaphragm is installed on the platform; A controller, installed on the support beam, is connected to the electric roller, the electromagnetic component, the first drive structure, the second drive structure, the linear module, the electric jacking component, the electric wrench, the torque sensor, the camera, and the distance sensor. The controller acquires the real-time distance. When the real-time distance meets a preset distance value, the controller acquires the image and identifies the bolt to be tightened on the crossbeam. After identifying the bolt, the controller controls the first drive structure, the second drive structure, and the linear module to coordinate and move the support platform so that the tightening bit is aligned with the bolt. After the tightening bit is aligned with the bolt, the controller controls the electric jacking component to engage the tightening bit with the bolt. After the tightening bit is engaged with the bolt, the controller controls the electric wrench to rotate the tightening bit and acquire the torque. When the torque reaches a preset torque, the controller shuts off the electric wrench.

2. The automatic tightening device for high-strength bolts for steel box girders according to claim 1, characterized in that, The electric rollers are rotatably mounted at opposite ends of the wheel frame, and the locking seat is disposed between the two electric rollers.

3. The automatic tightening device for high-strength bolts used in steel box girders according to claim 2, characterized in that, The locking seat is mounted vertically and flexibly in the middle of the wheel frame via a cylinder.

4. The automatic tightening device for high-strength bolts for steel box girders according to claim 1, characterized in that, The controller is located at one end of the support beam, and an automatic retractor is installed at the other end of the support beam.

5. The automatic tightening device for high-strength bolts for steel box girders according to claim 1, characterized in that, The distance sensors are multiple, and the multiple distance sensors are arranged along the circumferential direction of the electric wrench.

6. The automatic tightening device for high-strength bolts for steel box girders according to claim 5, characterized in that, The distance sensor is a laser distance sensor.

7. The automatic tightening device for high-strength bolts for steel box girders according to claim 1, characterized in that, The electric jacking component is an electro-hydraulic push rod.

8. The automatic tightening device for high-strength bolts for steel box girders according to claim 1, characterized in that, The first driving structure includes: A rack is installed on the groove wall of the slide; A gear is rotatably mounted on the slider and meshes with the rack; A transverse motor is driven by the gear and mounted on the movable base.

9. A construction method for an automatic tightening device for high-strength bolts used in steel box girders as described in any one of claims 1 to 8, characterized in that, Includes the following steps: The controller controls the electric rollers so that the screwdriver bit on the support beam is aligned with the transverse diaphragm of the steel box girder to be constructed. The distance sensor collects the real-time distance between the pier and the transverse diaphragm of the steel box girder; The controller acquires the real-time distance. When the real-time distance meets the preset distance value, the controller activates the locking seat and the electromagnetic component. The electromagnetic component is attracted to the steel box girder to lock the supporting beam. After locking the support beam, the controller acquires the image and identifies the bolts to be tightened on the diaphragm; After identifying the bolt to be tightened, the controller controls the first drive structure, the second drive structure, and the linear module to move the support platform in coordination so that the tightening bit is aligned with the bolt to be tightened; After the tightening bit is aligned with the bolt to be tightened, the controller controls the electric pusher to make the tightening bit fit onto the bolt to be tightened; After the screwdriver bit is fitted onto the bolt to be tightened, the controller controls the electric wrench to rotate the screwdriver bit and obtain the torque. When the torque reaches the preset torque, the controller turns off the electric wrench.

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