A prefabricated box girder positioning net welding algorithm

Abstract

The application discloses a prefabricated box girder positioning net welding algorithm and relates to the technical field of positioning net welding, and comprises data input; position data parameters corresponding to each positioning net are called out in sequence, the cutting length parameters of each steel bar are calculated by a steel bar straightening and shearing machine according to the called-out data parameters, then the steel bar straightening and shearing machine is controlled to cut, and a welding machine is controlled to weld according to preset welding parameters; welding inspection is conducted on the positioning net, unqualified problem position information is fed back to an upper computer for re-welding; qualified products are discharged; the beneficial effects are that the welding quality and efficiency of the prefabricated box girder positioning net are improved by accurately controlling the welding path and welding parameters, meanwhile, the algorithm has good universality and expansibility, can be widely applied to the manufacturing of different types of prefabricated box girders, in addition, the application can greatly improve the production efficiency, reduce manual intervention and reduce the production cost, and provides strong support for the manufacturing of prefabricated box girders.

Description

Technical Field

[0001] This invention relates to the field of positioning mesh welding technology, and in particular to a welding algorithm for positioning mesh of precast box girders. Background Technology

[0002] Precast box girders are widely used in the construction of highways, bridges, and other engineering projects. During the manufacturing process, positioning mesh is used to fix and support the embedded prestressed steel bars. The welding quality of the positioning mesh affects the installation of the prestressed steel bars, thus impacting the overall quality and safety of the precast box girder. However, traditional positioning mesh welding methods mostly involve manual assembly and welding, resulting in low welding efficiency and unstable welding quality. Therefore, improving the welding quality and efficiency of positioning mesh for precast box girders is an urgent problem to be solved. Summary of the Invention

[0003] The purpose of this invention is to provide a welding algorithm for the positioning mesh of precast box girders in order to solve the above-mentioned problems.

[0004] The present invention achieves the above objectives through the following technical solutions:

[0005] A welding algorithm for positioning mesh of precast box girder includes the following steps:

[0006] Step S1: Based on the number of positioning meshes set inside the precast box girder, group and sort the prestressed steel bar center position data corresponding to each positioning mesh, and input the corresponding data into the control system;

[0007] Step S2: Retrieve the data parameter corresponding to the sequence number n according to the requirements, where n is any integer from 0 to 32;

[0008] Step S3: Based on the retrieved data parameters, the rebar straightening and shearing machine calculates the cutting length parameters for each rebar, then controls the rebar straightening and shearing machine to cut, and controls the welding machine to weld according to the preset welding parameters;

[0009] Step S4: Inspect the welding of the positioning mesh. If it fails, send the problem location information back to the host computer and execute step S3; if it passes, proceed to the next step.

[0010] Step S5: Determine whether a set of positioning nets has been processed. If it has been processed, stop the machine. If it has not been processed, proceed to the next step.

[0011] Step S6: Retrieve the data parameters corresponding to sequence number n+1;

[0012] Step S7: Execute step S4.

[0013] Preferably, the prestressed steel reinforcement embedded positions in the precast box girder are symmetrical at both ends, that is, the positioning net inside the precast box girder can be divided into two sets of the same data corresponding to the two sides of the middle of the precast box girder. Therefore, when inputting data in step S1, only half of the positioning net data inside the precast box girder needs to be input, and the other half can be processed according to the same data.

[0014] Preferably, the prestressed steel bar center position data in step S1 refers to the coordinate position information in a coordinate system established with the middle position of the precast box girder as the origin, the horizontal direction as the X-axis, and the vertical direction as the Y-axis in the plane where each positioning network is located.

[0015] Preferably, in step S3, the rebar straightening and shearing machine obtains the length of the side vertical bars, the bottom vertical bars, and the position parameters of the side horizontal bars of the positioning mesh based on the system model and the position of each prestressed rebar. The bottom horizontal bars and the side vertical bars have the same position and direction, so the rebar straightening and shearing machine can cut and place the rebars. The welding machine can obtain the position of each rebar node through the system model and weld each rebar node.

[0016] Preferably, the welding inspection in step S4 includes visual inspection and mechanical inspection. Visual inspection involves scanning the weld joint with a laser sensor to obtain three-dimensional morphological data of the weld joint. Then, by analyzing this data, it is possible to detect whether there are defects in the weld joint, such as lack of fusion, slag inclusion, and porosity. At the same time, the geometric dimensions of the weld joint, such as weld width, height, and flatness, can also be measured. Mechanical inspection is performed by testing the compressive strength through a rolling test.

[0017] Compared with existing technologies, the beneficial effects of this invention are as follows: The precast box girder positioning mesh welding algorithm provided by this invention improves the welding quality and efficiency of the precast box girder positioning mesh by precisely controlling the welding path and welding parameters. At the same time, the algorithm has good versatility and scalability, and can be widely applied to the manufacturing of different types of precast box girders. In addition, the algorithm can be continuously optimized and improved based on actual working conditions and experimental data to further improve welding quality and efficiency. Compared with traditional positioning mesh welding methods, this invention can significantly improve production efficiency, reduce manual intervention, and lower production costs, providing strong support for the manufacturing of precast box girders. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1This is a flowchart of a welding algorithm for positioning mesh of a precast box girder as described in this invention.

[0020] Figure 2 This is a schematic diagram showing the distribution of the positioning mesh within the precast box girder in the welding algorithm for the positioning mesh of a precast box girder as described in this invention.

[0021] Figure 3 This is a diagram showing the positional relationship between the positioning mesh and prestressed steel bars in the welding algorithm for positioning mesh of a precast box girder as described in this invention.

[0022] Figure 4 This is the prestressed steel reinforcement position coordinate system of the precast box girder positioning mesh welding algorithm described in this invention.

[0023] Figure 5 This is a statistical table of the center positions of each prestressed steel bar in the precast box girder positioning mesh welding algorithm described in this invention.

[0024] The annotations in the attached figures are explained as follows:

[0025] 10. Bottom horizontal reinforcement; 11. Prestressed steel reinforcement; 12. Bottom vertical reinforcement; 13. Side vertical reinforcement; 14. Side horizontal reinforcement; 15. Side prestressed duct. Detailed Implementation

[0026] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. In addition, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation", "connection", and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood through the specific circumstances.

[0028] The present invention will be further described below with reference to the accompanying drawings:

[0029] like Figure 1 As shown, a welding algorithm for positioning mesh of precast box girder includes the following steps:

[0030] Step S1: As Figure 2 As shown, the pre-embedded positions of the prestressed steel bars 11 in the precast box girder are symmetrical at both ends. That is, the positioning network inside the precast box girder can be divided into two sets of identical data corresponding to the two sides of the mid-span of the precast box girder. The positioning network is named sequentially from the mid-span of the precast box girder to both sides using integers from 0 to 32, and the center position data parameters of the prestressed steel bars 11 corresponding to each positioning network are entered into the system using this sequence number. The center position data of the prestressed steel bars 11 refers to the coordinate position information in the coordinate system established with the midpoint of the bottom surface of the precast box girder as the origin, the horizontal direction as the X-axis, and the vertical direction as the Y-axis in the plane where each positioning network is located. Figure 4 As shown, the precast box girder cross-section is symmetrical on both sides, so only the center position data of the prestressed steel bar 11 on one side needs to be entered. The position data of each prestressed steel bar 11 at the corresponding position of each positioning grid are as follows: Figure 5 As shown;

[0031] Step S2: Retrieve the data parameter corresponding to the sequence number n according to the requirements, where n is any integer from 0 to 32;

[0032] Step S3: Based on the retrieved data parameters, the rebar straightening and shearing machine uses system modeling and the position of each prestressed rebar 11 to determine the length of the side vertical bar 13, the position parameters of the bottom vertical bar 12 and the side horizontal bar 14 of the positioning mesh. The bottom horizontal bar 10 and the side vertical bar 13 have the same position and direction, so the rebar straightening and shearing machine can cut and place the rebar. The welding machine can obtain the position of each rebar node through system modeling and weld each rebar node.

[0033] Step S4: Welding inspection of the positioning mesh is performed. If the mesh fails the inspection, the problem location information is fed back to the host computer, and step S3 is executed. If the mesh passes the inspection, proceed to the next step. Welding inspection includes visual inspection and mechanical inspection. Visual inspection involves scanning the weld joint with a laser sensor to obtain three-dimensional morphological data. By analyzing this data, defects such as incomplete fusion, slag inclusions, and porosity can be detected. At the same time, the geometric dimensions of the weld joint, such as weld width, height, and flatness, can be measured. Mechanical inspection is performed by rolling a test to detect compressive strength.

[0034] Step S5: Determine whether a set of positioning nets has been processed. If it has been processed, stop the machine. If it has not been processed, proceed to the next step.

[0035] Step S6: Retrieve the data parameters corresponding to sequence number n+1;

[0036] Step S7: Execute step S4.

[0037] When processing the positioning net inside the precast box girder, the sequence number of the first data retrieved in step S2 is 0. Once processing is complete, the positioning net inside half of the precast box girder can be obtained. When processing the positioning net inside the other half of the precast box girder, the sequence number of the first data retrieved in step S2 only needs to be 1. Once processing is complete, all the positioning nets inside the entire precast box girder can be obtained. If the machine stops unexpectedly or midway, when restarting processing, the sequence number of the first data retrieved in step S2 should be the smallest sequence number among the unprocessed positioning nets.

[0038] The rebar straightening and shearing machine, welding machine, and laser sensor are all general standard parts or components known to those skilled in the art. Their structure and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods, so they will not be described in detail here.

[0039] The foregoing has shown and described the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are only illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from the spirit and scope of the present invention, and all such changes and modifications fall within the scope of the present invention as claimed.

Claims

1. A welding algorithm for positioning mesh of precast box girder, characterized in that: Includes the following steps: Step S1: Based on the number of positioning meshes set in the precast box girder, group and sort the center position data of the prestressed steel bars (11) corresponding to each positioning mesh, and input the corresponding data into the control system; Step S2: Retrieve the data parameter corresponding to the sequence number n according to the requirements, where n is any integer from 0 to 32; Step S3: Based on the retrieved data parameters, the rebar straightening and shearing machine calculates the cutting length parameters for each rebar, then controls the rebar straightening and shearing machine to cut, and controls the welding machine to weld according to the preset welding parameters; Step S4: Inspect the welding of the positioning mesh. If it fails, send the problem location information back to the host computer and execute step S3; if it passes, proceed to the next step. Step S5: Determine whether a set of positioning nets has been processed. If it has been processed, stop the machine. If it has not been processed, proceed to the next step. Step S6: Retrieve the data parameters corresponding to sequence number n+1; Step S7: Execute step S4; Among them, the prestressed steel bars (11) in the precast box girder are symmetrical at both ends, that is, the positioning net inside the precast box girder can be divided into two sets of the same data corresponding to the middle two sides of the precast box girder. Therefore, when inputting data in step S1, only half of the positioning net data in the precast box girder needs to be input, and the other half can be processed according to the same data. The center position data of the prestressed steel bars (11) in step S1 refers to the coordinate position information in the coordinate system established with the middle position of the precast box girder as the origin, the horizontal direction as the X-axis, and the vertical direction as the Y-axis in the plane where each positioning net is located. In step S3, the steel bar straightening and shearing machine obtains the length of the side vertical bar (13), the bottom vertical bar (12), and the side horizontal bar (14) position parameters of the positioning net based on the system modeling and the position of each prestressed steel bar (11).

2. The welding algorithm for the positioning mesh of a precast box girder according to claim 1, characterized in that: The welding inspection in step S4 includes visual inspection and mechanical inspection. Visual inspection involves scanning the weld joint with a laser sensor to obtain the three-dimensional morphological data of the weld joint. Then, by analyzing this data, it is possible to detect whether there are defects in the weld joint. At the same time, it is also possible to measure the geometric dimensions of the weld joint. Mechanical inspection is to test the compressive strength through a rolling test.

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