An apparatus and method for batch cutting of full rounds on a portal flame cutting machine

Abstract

This invention discloses an apparatus and method for batch cutting of full-circle steel using a gantry flame cutting machine. The apparatus includes a batch cutting frame, adjustable support components for the level of the batch cutting frame, and temporary pads. The support components are evenly arranged around the perimeter of the batch cutting frame. The batch cutting frame includes a left side plate, a right side plate, and a grid plate. Each grid plate has several semi-circular slots, and a cut is made at the center of each semi-circular slot. The cut has a shape that matches the longitudinal section shape of the cutting nozzle at the end of the flame cutting machine torch. The method solves the problems of full-circle steel positioning, sparking during full-circle steel cutting, deformation and twisting of full-circle steel during cutting, and poor straightness of full-circle steel during cutting in the shipbuilding process by conducting backward and forward empty-walk tests of the gantry flame cutting machine and adjusting the torch and batch cutting frame in conjunction with the cut.

Description

Technical Field

[0001] This invention belongs to the field of shipbuilding technology, and particularly relates to an apparatus and method for batch cutting of full round steel bars using a gantry flame cutting machine. It is a process for batch cutting full round steel bars with diameters of 60mm and 80mm on a gantry flame cutting machine. Background Technology

[0002] Round steel is a raw material used in shipbuilding, typically for manufacturing structural components of the hull. During shipbuilding, round steel needs to be cut to achieve the required dimensions and shapes for the hull structure. This cutting process is a crucial step in shipbuilding, impacting the ship's strength, durability, and safety; therefore, precise control of the cutting dimensions and shape is essential to ensure the strength and safety of the hull structure.

[0003] The cutting of round steel involves radial and axial cutting. Radial cutting involves cutting the round steel to the length specified in the construction drawings, while axial cutting involves cutting the round steel in half to create semi-circular steel parts for assembly. The cut semi-circular steel parts are then installed onto the corresponding hull structures according to the construction drawings, and welding equipment is used to weld the assembled parts. Currently, most round steel cutting is done using flame cutting, typically using a flame cutting machine. Flame cutting machines include fully automatic gantry flame cutting machines and semi-automatic flame cutting machines.

[0004] Existing gantry flame cutting machines generally have adjustable speed and direction of travel and are equipped with a cutting platform. The parallel movement of the gantry flame cutting machine relative to the cutting platform is typically achieved through pulleys at the bottom of the machine and a frame track parallel to the cutting platform. These gantry flame cutting machines are equipped with an adjustable torch frame, which includes a longitudinal adjustment component for fixing the torch and adjusting its height vertically, and a transverse adjustment component for adjusting its position horizontally. However, because the process of cutting full-round steel into semi-circular steel requires high precision, precise positioning and addressing thermal deformation during the process are necessary to ensure straightness and the cutting quality of the semi-circular steel. The cutting platforms of existing gantry flame cutting machines cannot meet these requirements.

[0005] Therefore, in existing round steel cutting processes, semi-automatic flame cutting machines are generally used, and a dedicated platform is still required to place the round steel in a groove on the outside of the platform before cutting. A search reveals that Chinese utility model patent CN202479755U discloses a processing device for cutting round steel and trimming angle steel, which uses a semi-automatic flame cutting machine combined with a dedicated platform to cut single round steel bars. However, this method can only cut one round steel bar at a time, increasing manual workload and reducing output. Furthermore, operating a semi-automatic flame cutting machine requires operators with more technical knowledge and experience, leading to more instability factors and often requiring significant manpower and resources, yet the cutting effect remains unsatisfactory.

[0006] This is because round steel bars are solid, long strips of steel with a circular cross-section, and the diameter of round steel bars required for shipbuilding is relatively large, with common diameter specifications being 60mm and 80mm. Therefore, the temperature at the core of the cutting flame can reach 1000℃. If a conventional cutting frame is used, there is a high risk of large thermal deformation. In addition, because the round steel bars required for shipbuilding are long, and conventional cutting frames are often placed directly on the cutting platform without further fixation, during the cutting process, the front section of the round steel often cools down by the time the rear section is cut. Due to the principle of thermal expansion and contraction, the cooled front section of the round steel will tilt the entire cutting frame. This can cause the cutting to deviate and become distorted, making it impossible to align with the plane containing the central axis of the round steel. In addition, if the cutting platform or cutting frame is tilted, when cutting a single round steel bar, the tilt angle of the cutting torch can be adjusted to align with the plane containing the central axis of the round steel bar. However, during the cutting process, the points of thermal deformation will shift, and the fixing and anti-deformation effect of the existing dedicated platform will be reduced. When cutting round steel bars in batches, adjusting the tilt angle of the cutting torch one by one is not only complicated in terms of positioning, but also requires ensuring the straightness of each cutting torch on the round steel bar. Otherwise, product cutting defects will occur during the movement of the cutting machine.

[0007] In other words, during the current axial cutting process of full-circle steel, problems such as inaccurate positioning of the full-circle steel, sparking during cutting, deformation and twisting of the full-circle steel during cutting, and poor straightness during cutting are frequently encountered at the work site. At this time, it is necessary to reposition the steel before cutting, which is very troublesome. If positioning, sparking, deformation, and straightness cannot be guaranteed, it will lead to product cutting defects, affect the performance of use, produce unqualified products that do not meet the accuracy requirements, and cause unnecessary waste.

[0008] A search revealed that a Chinese utility model application with publication number CN203541707U discloses a deformation-resistant round steel cutting jig, which "includes two jig side panels arranged longitudinally on the left and right sides, and multiple jig templates arranged laterally between the jig side panels, with multiple round steel slots of different sizes opened on the upper edge of the jig templates according to the specifications of the round steel material." Although this utility model's deformation-resistant round steel cutting jig initially fixes the round steel by "inserting the round steel to be cut into the round steel slots corresponding to each jig template and pressing it as much as possible to the bottom of the round steel slots." However, this utility model does not take into account the high heat of the cutting flame used for large-diameter round steel. Even after considering the length of the round steel and the principle of thermal expansion and contraction, it still causes the entire cutting jig to move during the cutting process, resulting in cutting defects and poor straightness, thus making the cut semi-circular steel unqualified. Furthermore, the round steel slots on the jig template in this utility model are of different sizes, indicating that it is still used for cutting single full round steel bars. However, since the hull structure requires a large amount of semi-circular steel bars, cutting each single full round steel bar individually would result in low cutting efficiency, long working time, and would not effectively meet the needs of shipbuilding, increasing the waste of manpower and resources.

[0009] Therefore, a method for batch cutting of full-circle steel is needed that can quickly and accurately locate the cutting process and effectively prevent deformation and displacement. Summary of the Invention

[0010] The purpose of this invention is to provide an apparatus and method for batch cutting of full-circle steel using a gantry flame cutting machine, so as to solve the problems existing in the prior art described above.

[0011] To achieve the above and other related objectives, the present invention adopts the following technical solution:

[0012] This invention provides an apparatus and method for batch cutting of full-round steel bars using a gantry flame cutting machine, comprising the following steps: S1, preparing an apparatus for batch cutting of full-round steel bars using a gantry flame cutting machine:

[0013] S1-1. Prepare a gantry flame cutting machine;

[0014] S1-2. Prepare equipment for batch cutting of full-circle steel:

[0015] The device includes a batch cutting frame, a support component for adjusting the level of the batch cutting frame, and temporary pads;

[0016] The support components are evenly arranged around the perimeter of the batch cutting frame. Each support component includes a right-angle plate, a movable plate, and a limiting slider. The right-angle plate includes a vertical side plate and a horizontal side plate. The inner side of the movable plate is fixedly connected to the end face of the batch cutting frame, and the outer side of the movable plate is in contact with the inner wall of the vertical side plate of the right-angle plate. The movable plate can move up and down relative to the vertical side plate through the limiting slider and is fixed by fasteners. The horizontal side plate is used to be fixedly connected to the cutting platform.

[0017] The long side of the batch cutting frame is no greater than the length of the frame track of the gantry flame cutting machine. The batch cutting frame includes a left side plate, a right side plate, and a grid plate. The left side plate and the right side plate are arranged longitudinally parallel. n transversely parallel grid plates are fixedly connected between the left side plate and the right side plate. The grid plates are arranged sequentially from front to back on the batch cutting frame as the first grid plate, the second grid plate, ..., the (n-1)th grid plate, and the nth grid plate. Each grid plate has several semi-circular slots with diameters of 60mm and 80mm. The two diameter semi-circular slots are spaced apart on the same grid plate, and the opening positions of the semi-circular slots of the same diameter on each grid plate are corresponding. A cut is also opened at the center of each semi-circular slot, and the cut has a shape that matches the longitudinal section shape of the cutting nozzle at the end of the flame cutting machine torch.

[0018] S2. Place and adjust the position of the batch cutting rack so that it is parallel to the machine frame track;

[0019] S3. Install the cutting torch and adjust its position:

[0020] S3-1. Install the same number of cutting torches on the gantry flame cutting machine according to the number of round steel bars to be cut.

[0021] S3-2. Adjust the position of each cutting torch in sequence so that the cutting nozzle at the end of the cutting torch coincides with the cut at the position where the full round steel is to be installed;

[0022] S3-3. When the cutting nozzle and the cut cannot be aligned, adjust the horizontal level of the batch cutting frame in the left and right directions using the support and temporary pads.

[0023] S4. Conduct a backward empty-run test of the gantry flame cutter to confirm that each cutting nozzle always coincides with the corresponding cut on each grid plate during the process; if they do not coincide, adjust the level of the batch cutting frame in the front-to-back direction using the support and temporary pads.

[0024] S5. After completing the rearward walk test, fix the movable plates and right-angle plates on each support component in sequence with fasteners, and remove each temporary pad.

[0025] S6. Place each round steel bar into the semi-circular slot where the round steel bar is to be installed, ensuring that there is a first gap between the front end of the round steel bar and the first grating plate, and a second gap between the rear end of the round steel bar and the nth grating plate.

[0026] S7. Move the cutting moment forward to the second interval, ignite the torch flame and adjust it to generate a wind line. Adjust the cutting moment height so that the root of the wind line is higher than the highest point of the entire round steel surface. Perform a forward empty run test of the gantry flame cutting machine.

[0027] S8. After completing the forward empty-run test, fix the batch cutting frame at the current position;

[0028] S9. After preheating and adjusting the torch height, the cutting of the round steel is completed by adjusting the travel speed of the gantry flame cutter.

[0029] S10. Lift the cut semi-circular steel bars away from the batch cutting rack.

[0030] As a preferred technical solution, in step S1-2, a vertical rectangular movable hole is provided on the vertical side plate of the right-angle plate, and the limiting slider is provided with a protruding end that matches the shape of the movable hole. The limiting slider is T-shaped, the protruding end is inserted into the movable hole and the end face of the protruding end is in contact with the outer side of the movable plate, and the limiting slider is threadedly connected to the movable plate by bolts.

[0031] As a preferred technical solution, the specific steps of step S2 include: placing the batch cutting frame within the frame track range of the gantry flame cutting machine, measuring the straight-line distance L1 from the front end of the left side plate to the left frame track and the straight-line distance L2 from the rear end of the left side plate to the left frame track, and measuring and adjusting the batch cutting frame so that L2 is equal to L1.

[0032] As a preferred technical solution, the specific steps in step S3-2 include: controlling the gantry flame cutter to move horizontally above the first grid plate, then adjusting the position of each torch in sequence so that the torch falls at the cut position to be cut the whole round steel, and further adjusting the position of the torch so that the cutting nozzle at the end of the torch coincides with the cut.

[0033] As a preferred technical solution, the specific steps of step S3-3 include: when the cutting nozzle and the cut cannot be aligned, a temporary pad is placed between the lower end face of the movable plate of the support and the upper end face of the horizontal side plate of the right angle plate to adjust the horizontality of the batch cutting frame in the left and right directions until the cutting nozzle of each torch is aligned with the cut shape on the first grid plate.

[0034] As a preferred technical solution, the specific steps in step S4 include:

[0035] When the gantry flame cutter reaches the second grid plate, pause and observe.

[0036] If the lowest point of each cutting nozzle is lower than the lowest point of the cut on the corresponding position on the second grid plate, the level of the batch cutting frame in the front-to-back direction is adjusted by adjusting the support near the second grid plate until the lowest point of each cutting nozzle is not lower than the lowest point of the cut on the corresponding position on the second grid plate.

[0037] If the lowest point of each cutting nozzle is higher than the lowest point of the corresponding cut on the second grid plate, then operate the gantry flame cutter to continue moving above the nth grid plate and observe whether each cutting nozzle and the corresponding cut on the nth grid plate overlap.

[0038] When each cutting nozzle coincides with the corresponding cut on the nth grid plate, the levelness of the batch cutting frame in the front-back direction is qualified; when each cutting nozzle does not coincide with the corresponding cut on the nth grid plate, the levelness of the batch cutting frame in the front-back direction is adjusted by adjusting the support located at the rear end face of the batch cutting frame until the cutting nozzle of each torch coincides with the cut shape on the nth grid plate.

[0039] As a preferred technical solution, the specific steps in step S6 include: placing each round steel bar in a semi-circular slot for installing the round steel bar in sequence, adjusting the front and rear positions of each round steel bar so that there is a gap between the front end face of the round steel bar and the first grid plate, and a gap between the rear end face of the round steel bar and the nth grid plate, and applying force to each round steel bar in sequence so that each round steel bar is inserted into the semi-circular slot.

[0040] As a preferred technical solution, the specific steps in step S7 include: moving the torch forward using a gantry flame cutter to the position between the nth grating plate and the rear end face of the round steel, connecting the torch to the torch pipeline, igniting the torch flame with cutting oxygen by opening the pipeline, adjusting the cutting oxygen level to generate an air line, adjusting the cutting torque height so that the root of the air line is higher than the highest point of the round steel surface, and conducting a forward empty run test of the gantry flame cutter to confirm that the air line is always located in the center of the round steel during the process.

[0041] As a preferred technical solution, the specific steps in step S8 include: after the forward empty walk test is completed, the horizontal side plates of each right-angle plate are welded and fixed to the lower plane in sequence, so that the batch cutting frame is fixed at the current position.

[0042] As a preferred technical solution, the specific steps for adjusting the travel speed of the gantry flame cutter in step S9 include: when cutting a round steel bar with a diameter of 80 mm, the speed is 200 mm per minute; when cutting a round steel bar with a diameter of 60 mm, the speed is 240 mm per minute.

[0043] As described above, the present invention has the following beneficial effects:

[0044] (1) The present invention provides a device and method for batch cutting of round steel using a gantry flame cutting machine. The device is simple and easy to operate. Through the ingenious design of the gantry flame cutting machine and the device for cutting round steel, the requirement for batch cutting of round steel is perfectly solved.

[0045] (2) The present invention provides an apparatus and method for batch cutting of full round steel bars using a gantry flame cutting machine. By batch cutting multiple full round steel bars, the manual workload is saved, the complex semi-automatic cutting process is eliminated, and the cutting of full round steel bars into semi-round steel bars is strictly guaranteed, thereby improving the cutting quality.

[0046] (3) The device and method for batch cutting of full-circle steel in a gantry flame cutting machine of the present invention can limit the thermal deformation of the cutting platform and prevent deformation by uniformly fixing the support members around the cutting platform. At the same time, it can prevent material waste, increase the cutting accuracy, and ensure semi-circular cutting.

[0047] (4) The present invention provides a device and method for batch cutting of round steel in a gantry flame cutting machine. The straightness is adjusted by adjusting the relative position of the batch cutting frame and the frame track. The horizontality of the batch cutting frame is adjusted by combining the semi-circular slot design with the feature of the gantry frame moving along the frame track and by using temporary pads and support components. This ensures the quality of batch cutting.

[0048] (5) The apparatus and method for batch cutting of full round steel in a gantry flame cutting machine of the present invention replaces the work of marking positioning lines by performing backward empty walk test and forward empty walk test of the gantry flame cutting machine, avoiding the accumulation of positioning errors from multiple positioning, and also saving labor and time costs. Attached Figure Description

[0049] Figure 1 This is a three-dimensional schematic diagram of the present invention during the cutting of a full-circle steel.

[0050] Figure 2 This is a three-dimensional schematic diagram of the lateral adjustment component in this invention.

[0051] Figure 3 This is a three-dimensional schematic diagram of the longitudinal adjustment component in this invention.

[0052] Figure 4 This is a schematic diagram of the support structure in this invention.

[0053] The specific explanations of the reference numerals in the attached drawings are as follows: 1. Cutting platform; 21. Left side plate; 22. Right side plate; 23. Grating plate; 231. nth grating plate; 232. Semi-circular slot; 233. Cutting notch; 31. Right angle plate; 311. Movable hole; 32. Movable plate; 33. Limiting slider; 34. Fastener; 4. Temporary pad; 5. Gantry flame cutter; 51. Frame rail; 61. Cutting torch; 62. Cutting nozzle; 7. Adjustable torch holder; 71. Lateral adjustment assembly; 711. Lateral guide rail; 712. Lateral rack; 713. Moving slider; 714. Lateral adjustment screw; 72. Longitudinal adjustment assembly; 721. Clamping part; 722. Longitudinal rack; 723. Longitudinal adjustment screw; 8. Full round steel. Detailed Implementation

[0054] To better understand the purpose, structure, and function of this invention, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments.

[0055] In the description of this invention, it should be noted that the positional relationships indicated by terms such as "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" are based on the positional relationships shown in the accompanying drawings and are only for the purpose of facilitating the description of the embodiments of this invention and simplifying the description. They are not intended to indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific direction, and therefore should not be construed as a limitation of this invention.

[0056] Example

[0057] like Figures 1-4 As shown, this embodiment provides an apparatus and method for batch cutting of full-circle steel using a gantry flame cutting machine, including the following steps:

[0058] S1. Prepare an apparatus for batch cutting of full round steel bars 8 using a gantry flame cutting machine 5.

[0059] S1-1, Prepare the gantry flame cutting machine 5.

[0060] The gantry flame cutting machine 5 includes a movable gantry, an adjustable torch holder 7, a torch 61, torch 61 piping, and a cutting platform 1. The movable gantry includes a gantry frame, a frame track 51, and a control system for starting, stopping, and controlling the moving speed and direction. The frame track 51 is arranged parallel to the left and right sides of the cutting platform 1. The gantry frame is installed on the frame track 51 and can move back and forth relative to the cutting platform 1 along the frame track 51. The control system is equipped with a knob for adjusting the back and forth moving speed of the frame along the frame track 51 by controlling the motor. The adjustable torch holder 7 is installed on the gantry frame. The adjustable torch holder 7 includes a suspension bracket for suspending the torch 61 piping, a longitudinal adjustment component 72 for fixing the torch 61 and adjusting the height of the torch 61 vertically, and a lateral adjustment component 71 for adjusting the position of the torch 61 horizontally.

[0061] In this embodiment, the control system is existing technology and will not be described in detail here; the suspension bracket is fixedly installed on the upper surface of the gantry frame, the longitudinal adjustment component 72 is installed on the front surface of the gantry frame, and the longitudinal adjustment component 72 is fixedly connected to the lateral adjustment component 71 through an L-shaped connector. The lateral adjustment assembly 71 includes a lateral guide rail 711 with a lateral rack 712, a movable slider 713 that matches the lateral guide rail 711, and a lateral adjustment screw 714 with a lateral adjustment gear at its end. The movable slider 713 has a through hole, through which the lateral adjustment screw 714 passes and is fitted with a limit nut. The lateral guide rail 711 is fixedly installed on the front end face of the gantry frame, so the movable slider 713 can be detachably fitted onto the lateral guide rail 711. The number of movable sliders 713 is installed according to the number of round steel bars 8 to be cut. The depth of the lateral adjustment screw 714 passing through the slider is adjusted by the limit nut, so that the lateral adjustment gear at the end of the lateral adjustment screw 714 meshes with the lateral rack 712 on the lateral guide rail 711. By rotating the lateral adjustment screw 714, the movable slider 713 can move horizontally along the lateral guide rail 711. The longitudinal adjustment assembly 72 includes a clamping part 721, a longitudinal rack 722, and a longitudinal adjustment screw 723 with a longitudinal adjustment gear. The longitudinal adjustment gear meshes with the longitudinal rack 722, and the longitudinal rack 722 is fixed to the cutting torch 61. The cutting torch 61 passes through the clamping part 721, and the cutting torch 61 can be moved up and down by rotating the longitudinal adjustment screw 723.

[0062] S1-2. Prepare and place the device for batch cutting of full round steel bars 8.

[0063] The device includes a batch cutting frame, adjustable support components for the level of the batch cutting frame, and temporary pads 4. The support components are evenly distributed around the perimeter of the batch cutting frame, and the horizontal height of the support components is the same as the fixed connection points on the perimeter of the batch cutting frame. Each support component includes a right-angle plate 31, a movable plate 32, and a limiting slider 33. The right-angle plate 31 includes a vertical side plate and a horizontal side plate. The inner side of the movable plate 32 is fixedly connected to the end face of the batch cutting frame, and the outer side of the movable plate 32 is in contact with the inner wall of the vertical side plate of the right-angle plate 31. The movable plate 32 can move up and down relative to the vertical side plate via the limiting slider 33 and is fixed by fasteners 34. The initial position of 32 is the position where the lower end face of the movable plate 32 is in contact with the upper end face of the horizontal side plate. The horizontal side plate is used to fix and connect to the cutting platform 1, which can effectively strengthen the batch cutting frame, limit the thermal deformation of the batch cutting frame, and make the batch cutting frame and the cutting platform 1 form a whole, avoiding displacement of the batch cutting frame caused by thermal deformation, increasing the cutting accuracy, ensuring the cutting of semi-circular steel, and preventing material waste. In this embodiment, the temporary pad 4 is a wedge-shaped pad. The levelness of the batch cutting frame in the horizontal direction can be finely adjusted by the support member in conjunction with the temporary pad 4. Figure 4 As shown, in this embodiment, the right-angle plate 31 is made of angle iron. A vertical rectangular movable hole 311 is provided on the vertical side plate of the right-angle plate 31. The limiting slider 33 is provided with a protruding end that matches the shape of the movable hole 311. The limiting slider 33 is T-shaped. The protruding end is inserted into the movable hole 311 and the end face of the protruding end is in contact with the outer side of the movable plate 32. The limiting slider 33 is threadedly connected to the movable plate 32 by bolts.

[0064] In practical work, when the cutting platform 1 or the ground on which the batch cutting rack is placed is flat, the movable plates 32 of each support component are adjusted and fixed to the lowest position to achieve the horizontality of the batch cutting rack; when the area on which the batch cutting rack is placed is tilted or uneven, the horizontality of the batch cutting rack needs to be adjusted by the support components.

[0065] The long side of the batch cutting frame is not greater than the length of the frame track 51 of the gantry flame cutting machine 5. The batch cutting frame includes a left side plate 21, a right side plate 22 and a grid plate 23. The left side plate 21 and the right side plate 22 are arranged in parallel longitudinally. There are n horizontally parallel grid plates 23 fixedly connected between the left side plate 21 and the right side plate 22. The grid plates 23 are arranged in order from front to back according to their positions on the batch cutting frame: the first grid plate 23, the second grid plate 23, ..., the (n-1)th grid plate 23, and the nth grid plate 231. Each grating plate 23 is provided with several semi-circular slots 232, the diameters of which are 60mm and 80mm, respectively, for placing full round steel bars 8 with a diameter of 60mm and 80mm respectively; the semi-circular slots 232 with a diameter of 60mm and the semi-circular slots 232 with a diameter of 80mm are arranged at intervals on the same grating plate 23, and the semi-circular slots 232 with the same diameter are opened in corresponding positions on each grating plate 23. Each semi-circular slot 232 is further provided with a notch 233. The notch 233 is located at the center of the arc-shaped groove edge of the semi-circular slot 232, and the notch 233 has a shape that matches the longitudinal section shape of the nozzle 62 at the end of the flame cutting torch 61. The shape of the notch 233 is slightly larger than the longitudinal section shape of the nozzle 62, so that the nozzle 62 can pass through the notch 233 to achieve initial positioning during the first installation and inspection of the flame cutting machine. At the same time, it can provide a certain buffer space for high-temperature deformation and provide a support point for prying up the semi-circular steel after cutting. The notch 233 is completed by CNC cutting. Since the cross-sectional specifications of each semi-circular steel after cutting should be consistent, with the error controlled within ±1 mm, the shape of the notch 233 completed by CNC cutting in this embodiment is the shape of the longitudinal section shape of the No. 4 nozzle 62 expanded outward by 1 mm. Existing CNC cutting technology can achieve the cutting requirements of the notch 233 shape, which will not be elaborated here.

[0066] S2. Place and adjust the position of the batch cutting rack so that the left side plate 21 of the batch cutting rack is parallel to the long side of the frame track 51.

[0067] Adjust each movable plate 32 to its initial position. Then, place the batch cutting frame within the frame track 51 of the gantry flame cutting machine 5. Measure the straight-line distance L1 from the front end of the lower edge of the outer side of the left plate 21 to the left frame track 51 and the straight-line distance L2 from the rear end of the lower edge of the outer side of the left plate 21 to the left frame track 51. While keeping the straight-line distance L1 constant, adjust the position of the rear end of the lower edge of the outer side of the left plate 21 so that the straight-line distance L2 from the rear end of the lower edge of the outer side of the left plate 21 to the left frame track 51 is equal to L1. This achieves parallelism between the lower edge of the left plate 21 and the long side of the frame track 51. Since the left plate 21 and the right plate 22 are parallel, once the left plate 21 is parallel to the left frame track 51, the right plate 22 will naturally be parallel to the right frame track 51.

[0068] In this embodiment, the gantry flame cutting machine 5 is equipped with a cutting platform 1. The left and right sides of the cutting platform 1 are parallel to the frame track 51. Therefore, by placing the batch cutting frame on the cutting platform 1 and adjusting it so that the four sides of the batch cutting frame are parallel to the corresponding four sides on the cutting platform 1, the batch cutting frame can be centered and aligned.

[0069] S3. Install the cutting torch 61 and adjust its position.

[0070] S3-1. Based on the number of round steel bars 8 to be cut, install the same number of cutting torches 61 on the gantry flame cutting machine 5.

[0071] Several cutting torches 61 are installed on the adjustable torch holder 7 of the gantry flame cutting machine 5. The number of cutting torches 61 installed is the same as the number of round steel bars 8 to be cut. The pipes of the cutting torches 61 are arranged and suspended on the suspension frame. A cutting nozzle 62 for cutting round steel bars 8 with a diameter of 60-80mm is installed at the end of the cutting torches 61. The cutting nozzle 62 used is a No. 4 cutting nozzle 62. In this embodiment, there are 5 round steel bars 8 to be cut. Therefore, the same number of cutting torches 61 are fixedly installed on the gantry flame cutting machine 5 by means of the longitudinal adjustment component 72.

[0072] S3-2. Adjust the position of each cutting torch 61 in sequence so that the cutting nozzle 62 at the end of the cutting torch 61 coincides with the cut 233 at the position where the full round steel 8 is to be installed.

[0073] First, move the gantry flame cutter 5 horizontally above the first grid plate 23 and adjust the position of each torch 61 in sequence. Then, move each torch 61 horizontally in sequence to the top of the semi-circular slot 232 where the whole round steel 8 is to be installed by adjusting the horizontal screw 714. Then, move each torch 61 vertically downward to the semi-circular slot 232 where the whole round steel 8 is to be installed by adjusting the vertical screw 723. Finally, according to the cut 233 on the first grid plate 23, further adjust the position of the torch 61 of the flame cutter so that the cutting nozzle 62 of the torch 61 falls into the cut 233 and the shape of the cutting nozzle 62 coincides with the shape of the cut 233.

[0074] S3-3. When the cutting nozzle 62 and the cut 233 cannot be aligned, it indicates that the batch cutting frame is tilted in the left and right directions. At this time, by placing a temporary pad 4 between the lower end face of the movable plate 32 of the support member on the lower side of the batch cutting frame and the upper end face of the horizontal side plate of the right angle plate 31, the horizontality of the batch cutting frame in the left and right directions is adjusted until the cutting nozzle 62 of each cutting torch 61 is aligned with the shape of the cut 233 on the first grid plate 23.

[0075] S4. Conduct a backward empty-run test of the gantry flame cutting machine 5 to confirm that each cutting nozzle 62 always coincides with the corresponding cut 233 on each grid plate 23. If they do not coincide, adjust the level of the batch cutting frame in the front-back direction through the support components.

[0076] When the gantry flame cutter 5 reaches the second grid plate 23, pause for observation. If the lowest point of each cutting nozzle 62 is lower than the lowest point of the corresponding cut 233 on the second grid plate 23, adjust the support near the second grid plate 23 by placing a temporary pad 4 between the lower end face of the movable plate 32 of the support and the upper end face of the horizontal side plate of the right angle plate 31 to adjust the levelness of the batch cutting frame in the front-back direction until the lowest point of each cutting nozzle 62 is not lower than the lowest point of the corresponding cut 233 on the second grid plate 23. If the lowest point of each cutting nozzle 62 is higher than the lowest point of the corresponding cut 233 on the second grid plate 23, continue to move the gantry flame cutter 5 above the nth grid plate 231 and observe whether each cutting nozzle 62 coincides with the corresponding cut 233 on the nth grid plate 231. When each cutting nozzle 62 coincides with the corresponding cut 233 on the nth grid plate 231, the horizontality of the batch cutting frame in the front-back direction is deemed acceptable. When each cutting nozzle 62 does not coincide with the corresponding cut 233 on the nth grid plate 231, it indicates that the batch cutting frame is tilted in the front-back direction, with the tilt angle being higher in the front and lower in the back. In this case, by adjusting the support member located at the rear end face of the batch cutting frame, and placing a temporary pad 4 between the lower end face of the movable plate 32 of the support member and the upper end face of the horizontal side plate of the right-angle plate 31, the horizontality of the batch cutting frame in the front-back direction is adjusted until the cutting nozzle 62 of each torch 61 coincides with the shape of the cut 233 on the nth grid plate 231. At this time, combined with the parallel adjustment completed in step S2, the straightness of the torch 61 when moving horizontally on the batch cutting frame can be ensured.

[0077] S5. After completing the backward walk test, fix the movable plate 32 and right angle plate 31 on each support member in sequence with fasteners 34, and remove each temporary pad 4.

[0078] S6. Place the full round steel bar 8 and insert it into the semi-circular slot 232 of the batch cutting frame.

[0079] Each round steel bar 8 is placed sequentially in the semi-circular slot 232 where it is to be installed. The front and rear positions of each round steel bar 8 are adjusted so that there is a gap between the front end of the round steel bar 8 and the first grating plate 23, and a gap between the rear end of the round steel bar 8 and the nth grating plate 231. Force is applied to each round steel bar 8 sequentially to make it snap into the semi-circular slot 232. The reason for not snapping the round steel bars 8 into the first grating plate 23 and the nth grating plate 231 is to avoid the possibility of damage to the cut 233 during repeated cutting, to ensure that the position of the cutting torch 61 can always be positioned through the first grating plate 23 and the nth grating plate 231, and at the same time, the horizontal tilt of the batch cutting frame in the left-right and front-back directions can be checked and adjusted through the first grating plate 23 and the nth grating plate 231.

[0080] The 60mm diameter and 80mm diameter round steel bars 8 can be placed in the corresponding semi-circular slots 232 with diameters of 60mm and 80mm respectively on the batch cutting rack according to their respective diameters; however, considering the large amount of thermal deformation caused by flame cutting during batch cutting, only the same diameter round steel bars 8 are placed in each batch cutting, that is, there is at least one slot between the same diameter round steel bars 8.

[0081] In this embodiment, five 80mm diameter round steel bars 8 are placed sequentially in the 80mm semi-circular slot 232 of the device for cutting the round steel bars 8. Each round steel bar 8 is spaced apart by a 60mm diameter semi-circular slot 232. Each round steel bar 8 is placed starting from the (n-2)th grid plate 23. The front end of each round steel bar 8 is spaced apart from the first grid plate 23, and the rear end of each round steel bar 8 is spaced apart from the nth grid plate 231. The spaced distances are used for subsequent adjustment of the flame of the cutting torch 61.

[0082] S7. Move the cutting moment forward to the second interval, ignite the flame of the cutting torch 61 and adjust it to generate a wind line. Adjust the height of the cutting moment so that the root of the wind line is higher than the highest point of the surface of the round steel 8, and conduct a forward empty run test of the gantry flame cutting machine 5.

[0083] Using the gantry flame cutter 5, the torch 61 is moved forward to the position between the nth grating plate 231 and the rear end face of the round steel 8. The torch 61 is then connected to the torch 61 pipeline. By opening the pipeline, the flame of the torch 61 is ignited using cutting oxygen. The amount of cutting oxygen is adjusted to generate an airflow. The height of the torch 61 is adjusted using the longitudinal adjusting screw 723 until the airflow is sufficiently far from the round steel 8. In this embodiment, the distance is 100mm, ensuring that the root of the airflow is higher than the highest point of the surface of the round steel 8, i.e., the lowest point of the blue flame of the airflow is higher than the surface of the round steel 8. This avoids the need for testing while moving forward empty. During the cutting process, when the round steel 8 is cut, a forward idle test is performed on the gantry flame cutting machine 5. During the idle test, visual observation is conducted to ensure that the root of the air line is always aligned with the round steel 8. The air line generated at the cutting nozzle 62 of the torch 61 is ultimately located in the center of the round steel 8. Generally, there will be no deviation after the adjustment in steps S2 to S4. However, if a deviation is observed, the levelness and straightness of the batch cutting frame are checked again. The levelness of the batch cutting frame is adjusted by adjusting the support components, and the straightness is adjusted by adjusting the relative position of the batch cutting frame and the frame track 51.

[0084] The simulated travel test by no-load testing replaced the work of marking positioning lines, avoiding the accumulation of positioning errors from multiple positioning attempts, and also saving labor and time costs. If the work of marking positioning lines is added, the first positioning adjustment needs to be performed when marking the positioning lines, and the second positioning needs to be performed when placing the full round steel 8 on the platform. Furthermore, a third positioning may be required between the cutting torch 61 and the full round steel 8, which is not only complicated to operate, but may also cause the accumulation of positioning errors.

[0085] S8. After completing the forward empty-walk test, the batch cutting frame is fixed at the current position by welding and fixing the lower end face of the horizontal side plate of each right-angle plate 31 to the upper end face of the cutting platform 1 in sequence.

[0086] S9. After preheating and adjusting the height of the cutting torch 61, the cutting of the full round steel 8 is completed by adjusting the travel speed of the gantry flame cutter 5.

[0087] Preheat the machine before cutting and adjust the height of the cutting torch 61. Adjust the distance between the cutting torch 61 and the surface of the round steel 8 according to the diameter of the round steel 8 to avoid cutting too high and failing. Then control the gantry flame cutter 5 to advance at the set cutting speed. When cutting a round steel 8 with a diameter of 80 mm, the speed is 200 mm per minute; when cutting a round steel 8 with a diameter of 60 mm, the speed is 240 mm per minute. The speed should be slightly slower at the beginning of the cutting, generally about 80% of the above speed. After cutting 200-300 mm, adjust the speed to the above standard speed. This is the optimal state, that is, after observing that the cut end face is neat and there is no slag at the bottom, adjust the speed to the above standard speed.

[0088] S10. After cooling, the cut semi-circular steel bars are lifted off the batch cutting rack. The cut slits 233 can be used to assist in separating the cut semi-circular steel bars sequentially from the batch cutting rack. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Those skilled in the art can make various changes or equivalent substitutions to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A method for batch cutting of full-circle steel using a gantry flame cutting machine, characterized in that, Includes the following steps, S1. Prepare an apparatus for batch cutting of full-circle steel (8) using a gantry flame cutting machine (5): S1-1, Prepare the gantry flame cutting machine (5); S1-2, Prepare the equipment for batch cutting of full-circle steel (8): The device includes a batch cutting frame, a support component for adjusting the level of the batch cutting frame, and a temporary pad (4); The support components are evenly arranged around the periphery of the batch cutting frame. The support components include a right-angle plate (31), a movable plate (32), and a limiting slider (33). The right-angle plate (31) includes a vertical side plate and a horizontal side plate. The inner side of the movable plate (32) is fixedly connected to the end face of the batch cutting frame. The outer side of the movable plate (32) is in contact with the inner wall of the vertical side plate of the right-angle plate (31). The movable plate (32) can move up and down relative to the vertical side plate through the limiting slider (33) and is fixed by fasteners (34). The horizontal side plate is used to be fixedly connected to the cutting platform (1). The long side of the batch cutting frame is not greater than the length of the frame track (51) of the gantry flame cutting machine (5). The batch cutting frame includes a left side plate (21), a right side plate (22), and a grid plate. The left side plate (21) and the right side plate (22) are arranged in parallel longitudinal direction. n horizontally parallel grid plates are fixedly connected between the left side plate (21) and the right side plate (22). The grid plates are arranged in order from front to back according to their position on the batch cutting frame as the first grid plate, the second grid plate, ..., the (n-1)th grid plate, and the nth grid plate. Each of the two types of semicircular slots (232) is provided with a number of semicircular slots (232) with diameters of 60mm and 80mm respectively. The two types of semicircular slots (232) are spaced apart on the same grid plate, and the semicircular slots (232) of the same diameter are positioned correspondingly on each grid plate. A notch (233) is also provided in the center of each semicircular slot (232), and the notch (233) has a shape that matches the longitudinal section shape of the cutting nozzle (62) at the end of the flame cutting torch (61). S2. Place and adjust the position of the batch cutting rack so that the batch cutting rack is parallel to the frame track (51); S3. Install the cutting torch (61) and adjust its position: S3-1. Based on the number of round steel bars (8) to be cut, install the same number of cutting torches (61) on the gantry flame cutting machine (5); S3-2. Adjust the position of each cutting torch (61) in sequence so that the cutting nozzle (62) at the end of the cutting torch (61) coincides with the cut (233) at the position where the full round steel (8) is to be installed; S3-3. When the cutting nozzle (62) and the cut (233) cannot be aligned, adjust the horizontal level of the batch cutting frame in the left and right directions by using the support and temporary pad (4). S4. Conduct a backward empty-run test of the gantry flame cutting machine (5) to confirm that each cutting nozzle (62) always coincides with the corresponding cut (233) on each grid plate during the process; if they do not coincide, adjust the level of the batch cutting frame in the front and rear directions by using the support and temporary pad (4). S5. After completing the backward walk test, fix the movable plate (32) and right angle plate (31) on each support in sequence with fasteners (34), and remove each temporary pad (4). S6. Place each round steel bar (8) and insert it into the semi-circular slot (232) where the round steel bar (8) is to be installed, ensuring that there is a first gap between the front end face of the round steel bar (8) and the first grid plate, and a second gap between the rear end face of the round steel bar (8) and the nth grid plate. S7. Move the cutting torch (61) forward to the second interval, ignite the flame of the cutting torch (61) and adjust it to generate a wind line. Adjust the height of the cutting torch (61) so that the root of the wind line is higher than the highest point of the surface of the round steel (8). Perform a forward empty run test of the gantry flame cutting machine (5). S8. After completing the forward empty-run test, fix the batch cutting frame at the current position; S9. After preheating and adjusting the height of the cutting torch (61), the cutting of the whole round steel (8) is completed by adjusting the travel speed of the gantry flame cutter (5). S10. Lift the cut semi-circular steel bars away from the batch cutting rack.

2. The method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, In step S1-2, a vertical rectangular movable hole (311) is provided on the vertical side plate of the right angle plate (31). The limiting slider (33) is provided with a protruding end that matches the shape of the movable hole (311). The limiting slider (33) is T-shaped. The protruding end is inserted into the movable hole (311) and the end face of the protruding end is in contact with the outer side of the movable plate (32). The limiting slider (33) is threadedly connected to the movable plate (32) by bolts.

3. The method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps of step S2 include: placing the batch cutting frame within the frame track (51) of the gantry flame cutting machine (5), measuring the straight distance L1 from the front end of the left side plate (21) to the left frame track (51) and the straight distance L2 from the rear end of the left side plate (21) to the left frame track (51), and measuring and adjusting the batch cutting frame so that L2 is equal to L1.

4. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps in step S3-2 include: controlling the gantry flame cutter (5) to move horizontally above the first grid plate, and then adjusting the position of each torch (61) in sequence so that the torch (61) falls at the cut (233) position for cutting the whole round steel (8), and further adjusting the position of the torch (61) so that the cutting nozzle (62) at the end of the torch (61) coincides with the cut (233).

5. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps of step S3-3 include: when the cutting nozzle (62) and the cut (233) cannot be aligned, a temporary pad (4) is placed between the lower end face of the movable plate (32) of the support and the upper end face of the horizontal side plate of the right angle plate (31) to adjust the horizontality of the batch cutting frame in the left and right directions until the cutting nozzle (62) of each cutting torch (61) is aligned with the cut (233) on the first grid plate.

6. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps in step S4 include: When the gantry flame cutter (5) reaches the second grid plate, pause for observation; If the lowest point of each cutting nozzle (62) is lower than the lowest point of the corresponding cut (233) on the second grid plate, the level of the batch cutting frame in the front-back direction is adjusted by adjusting the support near the second grid plate until the lowest point of each cutting torch (61) cutting nozzle (62) is not lower than the lowest point of the corresponding cut (233) on the second grid plate. If the lowest point of each cutting nozzle (62) is higher than the lowest point of the corresponding cut (233) on the second grid plate, then operate the gantry flame cutter (5) to continue moving to the top of the nth grid plate and observe whether each cutting nozzle (62) and the corresponding cut (233) on the nth grid plate overlap. When each cutting nozzle (62) coincides with the corresponding cut (233) on the nth grid plate, the levelness of the batch cutting frame in the front-back direction can be determined to be qualified; when each cutting nozzle (62) does not coincide with the corresponding cut (233) on the nth grid plate, the levelness of the batch cutting frame in the front-back direction is adjusted by adjusting the support located at the rear end face of the batch cutting frame until the cutting nozzle (62) of each cutting torch (61) coincides with the shape of the cut (233) on the nth grid plate.

7. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps in step S6 include: placing each round steel bar (8) in the semi-circular slot (232) where the round steel bar (8) is to be installed, adjusting the front and rear positions of each round steel bar (8) so that there is a gap between the front end face of the round steel bar (8) and the first grid plate, and there is also a gap between the rear end face of the round steel bar (8) and the nth grid plate, and applying force to each round steel bar (8) in sequence so that each round steel bar (8) is inserted into the semi-circular slot (232).

8. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps in step S7 include: moving the torch (61) forward to the position between the nth grating plate and the rear end face of the round steel (8) using the gantry flame cutter (5), connecting the torch (61) to the torch pipeline, igniting the torch (61) flame with cutting oxygen by opening the pipeline, adjusting the cutting oxygen size to generate a wind line, adjusting the height of the torch (61) so that the root of the wind line is higher than the highest point of the surface of the round steel (8), and conducting a forward empty run test of the gantry flame cutter (5) to confirm that the wind line is always located in the center of the round steel (8) during the process.

9. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, The specific steps in step S8 include: after the forward empty walk test is completed, the horizontal side plates of each right angle plate (31) are welded and fixed to the lower plane in sequence, so that the batch cutting frame is fixed at the current position.

10. A method for batch cutting of full-circle steel using a gantry flame cutting machine according to claim 1, characterized in that, In step S9, the specific steps for adjusting the travel speed of the gantry flame cutter (5) include: when cutting a round steel bar (8) with a diameter of 80 mm, the speed is 200 mm per minute; when cutting a round steel bar (8) with a diameter of 60 mm, the speed is 240 mm per minute.

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