A combined high-altitude welding method and system

Abstract

The present application relates to a kind of combined high-altitude welding method and system.The method includes one or more of the following steps: before performing welding operation, the construction site is scanned using a detection module to obtain image information related to the target to be welded in the construction site, so as to obtain the position information of the area to be welded by analysis;Drive execution module and auxiliary module to complete the welding operation and / or independently drive execution module or auxiliary module to complete the welding operation with the operator;After performing welding operation, the construction site is scanned using a detection module to obtain image information related to the target to be welded in the construction site, so as to obtain the score of the welding operation quality by analysis.The system includes: a central control module for generating control signals;Execution module for executing welding process operation according to the control signal generated by the central control module;Auxiliary module for executing welding auxiliary operation according to the control signal generated by the central control module.

Description

Technical Field

[0001] This invention relates to the field of high-altitude welding technology, and in particular to a combined high-altitude welding method and system. Background Technology

[0002] High-altitude welding is a crucial technology in the construction and engineering fields. It requires not only solid welding skills but also exceptional experience and expertise in working at heights. High-altitude welding focuses on welding in high-altitude environments, such as buildings, bridges, and oil platforms. This is an extremely dangerous and challenging job, demanding strong mental fortitude and a high level of professionalism from welders. High-altitude welding technology has a wide range of applications, ensuring the strength and safety of buildings and facilities while improving construction efficiency and quality. However, facing the various difficulties and risks associated with high-altitude environments, high-altitude welders need outstanding technical skills and professional ethics. They must strictly adhere to safety operating procedures, correctly use and maintain welding equipment, and continuously improve their professional level through ongoing training and learning. The development of high-altitude welding technology relies heavily on technological support. The emergence of modern high-altitude welding equipment has greatly improved welding efficiency and safety. The application of automated welding equipment and intelligent monitoring systems makes high-altitude welding work more efficient and stable.

[0003] CN115156782A discloses an automatic welding device suitable for high-altitude operations, including a multi-scenario load-bearing clamping mechanism, a vertical lifting and adjusting mechanism, a welding machine storage counterweight mechanism, and a horizontal adjusting mechanism. The vertical lifting and adjusting mechanism is located above the multi-scenario load-bearing clamping mechanism, and the welding machine storage counterweight mechanism is located on one side above the vertical lifting and adjusting mechanism. The horizontal adjusting mechanism is located on the side of the welding machine storage counterweight mechanism. This automatic welding device for high-altitude operations allows for effective fine-tuning of the welding angle of the workpiece when welding at locations requiring precise angle adjustments is difficult. With the activation of a second servo motor, the threaded adjustment between the bevel gear set and the rotating shaft allows for effective fine-tuning of the welding angle. Even if the welding head of the workpiece malfunctions, it can be removed and replaced using the threaded assembly, improving safety and portability during high-altitude welding operations.

[0004] CN114012211A discloses a high-altitude automatic welding equipment and method, including an automatic welding machine for performing welding on a weld seam according to welding process parameters; a visual recognition system for identifying weld seam position information and acquiring weld seam image information, transmitting the weld seam position information to the automatic welding machine, and transmitting the weld seam image information to a remote control center or mobile control device; a remote control center for issuing welding process parameters to the automatic welding machine and receiving the weld seam image information transmitted from the visual recognition system, enabling on-site remote real-time monitoring; and a mobile control device for issuing welding process parameters to the automatic welding machine and receiving the weld seam image information transmitted from the visual recognition system, enabling on-site real-time monitoring.

[0005] CN109986250A discloses a welding device, more specifically a multifunctional high-altitude automatic welding robot, including a mounting base, a moving device, a position adjustment device, a height adjustment device, a welding workpiece parallel device, and a welding device. It enables the moving device to move on a high-altitude wall, the position adjustment device to adjust the lateral position of the welding workpiece parallel device, the height adjustment device to adjust the height of the welding workpiece parallel device, the welding workpiece parallel device to adjust the height of two welding workpieces, and the welding device to perform welding on the workpieces. The moving device is mounted and fixed on the mounting base, the position adjustment device is mounted and fixed on the mounting base, the height adjustment device is mounted and fixed on the moving bottom device, the welding workpiece parallel device is mounted and fixed on the moving inner rod, and the welding workpiece parallel device is mounted and fixed on the mounting base.

[0006] Unlike conventional welding processes, slag spatter is an unavoidable problem in high-altitude welding. To address slag collection, heat-resistant slag collection devices (such as heat collection buckets) made of high-temperature resistant materials are typically placed below the welding point. These heat collection buckets possess excellent heat resistance, able to withstand the sparks and flames generated during high-temperature welding. Existing heat collection buckets are usually configured as independent collection devices, meaning they are mostly manually hoisted by operators to place below the welding point to block and collect slag. However, many high-altitude welding processes require welding operations at multiple points, such as welding reinforcing bars in wet joints and / or wet seams in bridge engineering. Relying on manually hoisting heat collection buckets would significantly slow down the construction progress because it requires frequent relocation of the bucket's installation position. Furthermore, the current welding slag collection bucket only has a collection function, that is, it can only passively collect the welding slag generated during the welding process, and cannot actively participate in the welding process to achieve effective linkage with other equipment. This wastes the effective data that the welding slag collection bucket can obtain. This effective data cannot be obtained by the welding equipment, but it can characterize the accuracy of the welding process of the welding equipment.

[0007] Furthermore, on the one hand, there are differences in understanding among those skilled in the art; on the other hand, the applicant studied a large number of documents and patents when making this invention, but due to space limitations, not all details and contents were listed in detail. However, this does not mean that the present invention does not possess the features of these prior art. On the contrary, the present invention already possesses all the features of the prior art, and the applicant reserves the right to add relevant prior art to the background art. Summary of the Invention

[0008] Existing technologies have already developed technical solutions for using unmanned aerial vehicle (UAV) systems to collect welding information in order to improve welding efficiency in dispersed welding environments. For example, patent document CN112440040A discloses a system and method for using UAVs in dispersed welding environments, including collecting welding information from welding equipment, workpieces, or welds via the UAV, and forwarding the welding information from the UAV to a monitoring device communicating with the UAV. This technical solution collects welding information by locating or identifying the welding equipment, workpiece, or weld via the UAV's detection device or communication circuit system, and connects the welding tools of the welding equipment to an attachment device on the UAV to move the corresponding welding equipment according to the collected welding information. The UAV equipment involved in this technical solution only involves adjusting the position of the corresponding welding equipment by collecting welding information in a specific welding environment. However, it cannot determine the specific welding parameters of the welding equipment or the specific placement relationship between the welding equipment performing the welding operation and the corresponding collection device. Consequently, it cannot improve the performance of the welding operation process, nor can it provide adequate protection against welding spatter in complex construction environments. Therefore, this technical solution cannot adjust the placement of the welding execution component and the welding collection component according to the actual welding spatter situation at the construction site, and thus cannot achieve higher overall welding quality. Furthermore, the drone in this technical solution only involves detecting welding position information to provide a basis for transferring welding equipment; it cannot score the performed welding operation to evaluate the corresponding welding quality.

[0009] In view of the shortcomings of the prior art, the present invention provides a combined high-altitude welding operation method and system to solve at least some of the above-mentioned technical problems.

[0010] This invention discloses a combined high-altitude welding method, comprising one or more of the following steps: before performing the welding operation, a detection module scans the construction site to obtain image information related to the target to be welded, thereby analyzing the location information of the area to be welded; a drive execution module and an auxiliary module work together in combination to complete the welding operation, and / or the drive execution module or auxiliary module independently assists the operator in completing the welding operation; after performing the welding operation, the detection module scans the construction site to obtain image information related to the target to be welded, thereby analyzing the welding operation quality score. The execution module for performing the welding process and the auxiliary module for performing welding auxiliary operations can complete the welding operation in a cross-control manner.

[0011] Unlike existing technologies, the execution module and auxiliary module of this invention can perform corresponding welding operations in multiple working modes. The control relationship between the execution module and auxiliary module is adjusted according to the actual working state of the welding operation, and the welding quality can be further evaluated through a detection module after the welding operation. Based on the above-mentioned distinguishing technical features, the problems to be solved by this invention include: how to adjust the cooperation mode of the execution module and auxiliary module according to the actual operational requirements of the welding operation to improve the completion efficiency and quality of the welding operation, and how to evaluate the quality of specific welding operations. Specifically, in actual high-altitude welding operations, the specific welding position and welding parameters will affect the specific working effect of the execution module and auxiliary module. For example, when the welding position or welding parameters are adjusted, the spatter path will also change, thus requiring adjustment of the positional relationship between the execution module and auxiliary module to achieve stable and accurate spatter collection. This invention can combine the execution module and auxiliary module to perform corresponding welding operations, thereby adjusting the cooperation relationship between the execution module and auxiliary module according to changes in the welding position or welding parameters to provide a more accurate and comprehensive spatter collection and protection effect. Preferably, the welding process operation can be an operation method that joins metals or other thermoplastic materials by heating, high temperature, or high pressure, such as gas welding, resistance welding, and arc welding. Welding auxiliary operations can be operation methods that assist the welding process operation, such as catching hot weld spatter, fixing or supporting objects, etc. Preferably, cross-control refers to the execution module generating control signals to regulate the operating parameters of the auxiliary module, so that the welding auxiliary operations performed by the auxiliary module can be adapted to the welding process operation performed by the execution module. Furthermore, the auxiliary module can generate control signals to regulate the operating parameters of the execution module, so that the execution module can adjust its welding process operation according to the control signals transmitted by the auxiliary module, thereby ensuring welding quality. For example, when the execution module switches and moves the target to be welded, the auxiliary module can adaptively move or adjust to ensure that the new target to be welded is within the operating range of its welding auxiliary operations. As another example, when the auxiliary module determines that there is a deviation in the welding process based on the collected data related to the welding process, it can drive the execution module to adjust its operating parameters to correct the welding process operation. This configuration allows the execution module and auxiliary module of the present invention to work together effectively in conjunction to complete the welding operation, ensuring a high degree of automation and precision in the welding process. Furthermore, the execution module and auxiliary module of the present invention also retain the ability to operate independently to adapt to different operational needs.For example, for certain welding tasks that are extremely difficult or involve complex operations, current automated welding equipment cannot handle them perfectly, and experienced welders still need to be dispatched for manual operation. In such cases, an auxiliary module can be driven independently to assist the operator in completing the welding operation. As another example, for situations where the risk of weld slag falling is low, especially when it is difficult to install a flare-catching device below the welding point, an execution module can be driven independently to perform the welding process.

[0012] According to a preferred embodiment, when the central control module drives the execution module and the auxiliary module to jointly complete the welding operation, the temperature distribution inside the receiver obtained by the third monitoring unit installed in the receiver for collecting welding slag in the auxiliary module can be used to adjust the operating parameters of the execution module.

[0013] Unlike existing technologies, the auxiliary module of this invention can adjust the operating parameters of the execution module based on the real-time temperature distribution information within the receiver obtained by the third monitoring unit installed on the receiver. Based on these distinguishing technical features, the problem this invention aims to solve can include: how to determine specific spatter collection information based on temperature changes on the inner surface of the receiver, in order to verify the accuracy of the preset execution module operating parameters when performing the corresponding welding process. Specifically, the third monitoring unit of this invention can be configured as several temperature sensors arranged in an array on the inner surface of the receiver to obtain the temperature value of the spatter falling onto the inner surface of the receiver. The third monitoring unit can feed back the real-time temperature values ​​obtained by each temperature sensor to the control unit, so that the control unit can generate temperature distribution images of the inner surface of the receiver at various times. The temperature sensors within the receiver can periodically collect real-time temperature data and send the temperature distribution within the receiver at the same time to the control unit in the form of slices, so that the control unit can generate temperature distribution images at corresponding times based on the changes in temperature distribution within the receiver over time. Preferably, the control unit can determine the increment and distribution location of weld slag falling based on temperature distribution images at various times, thereby simulating the evolution process of weld slag falling onto the inner surface of the receiver and determining the accuracy of the welding process operation. The control unit can adjust the operating parameters of the execution module's operating unit based on data information obtained from the third monitoring unit. For example, if the control unit determines that the increment of weld slag falling in the receiver per unit time exceeds a set threshold and / or the increment of weld slag falling in the receiver within a unit area exceeds a set threshold, it can adjust the operating parameters of the execution module's operating unit. The adjustment methods may include changing the welding angle, controlling the current and voltage, and adjusting the welding speed.

[0014] According to a preferred embodiment, a receiver comprising a fixed plate and a plurality of flip plates is movably connected to an adjusting rod, such that when the adjusting rod is fixed, the receiver can reciprocate along a groove opened thereon under external driving action to adjust the relative position of the receiver and the adjusting rod, and / or can rotate around the connection structure between the receiver and the adjusting rod under external driving action, so that the receiver completes a partial angle deflection in a specified direction.

[0015] Unlike existing technologies, the receiver of this invention can be movably connected to the adjusting rod structure and can perform reciprocating linear motion or angular deflection relative to the adjusting rod in a single direction. Based on the above-mentioned distinguishing technical features, the problem to be solved by this invention may include: how to adjust the positional relationship between the receiver and the execution module in the auxiliary module so that it can accurately collect the welding slag that falls during the welding operation. Preferably, the adjusting rod of this invention can have multiple adjustment dimensions so that the receiver can be adjusted in the horizontal and / or vertical directions. The auxiliary module can determine the adjustment scheme of the adjusting rod according to the three-dimensional model generated by the central control module to avoid the adjusting rod and / or the receiver from colliding with other building structures. The receiver, which can reciprocate along the opening direction of the chute under the drive of a motor, can be set in a manner that partially offsets relative to the adjusting rod, thereby adapting to various welding situations (e.g., entering a space from the side that is difficult to enter directly from the front). The connection structure between the receiver and the adjusting rod may include a spherical rotating element, which can be driven to complete a partial angular rotation in a specified direction. This ensures that even if the third motion unit is partially offset due to the unevenness of the precast beam surface, the receiver can still remain relatively level, thus preventing the weld slag falling into the receiver from rolling and colliding within it.

[0016] According to a preferred embodiment, when the construction site is a precast beam bridge deck for a bridge project, the second motion unit configured in the execution module and the third motion unit configured in the auxiliary module are respectively set on both sides of the wet joint or wet seam to be welded, so that the execution module and the auxiliary module can perform corresponding operations at different angles.

[0017] Unlike existing technologies, both the execution module and the auxiliary module of this invention are equipped with motion units capable of adjusting their positions. Based on the aforementioned distinguishing technical features, the problem to be solved by this invention can include: how to adjust the positional relationship between the execution module and the auxiliary module according to different welding operations, so as to improve the efficiency of site transitions between different welding operations. Specifically, in a preferred embodiment of this invention, the execution module and the auxiliary module work together in combination to complete the welding operation. When the construction site is a precast beam bridge deck of a bridge project, and the target to be welded is a wet joint and / or wet seam, the execution module can move on the precast beam using its configured second motion unit, and the auxiliary module can move on the precast beam using its configured third motion unit. To avoid conflicts in their operating paths, the second motion unit and the third motion unit can be respectively set on both sides of the wet joint or wet seam to be welded.

[0018] According to a preferred embodiment, when the execution module and / or auxiliary module need to cross a wet joint or wet seam, a crossing unit configured on the execution module and / or auxiliary module is used to accomplish this. The crossing unit includes an extension rod that can extend and retract in the horizontal direction and a support rod that can extend and retract in the vertical direction. The second motion unit and the third motion unit can move along the corresponding extension rod without contacting the surface of the currently located precast beam to move above the adjacent precast beam.

[0019] When the second and third motion units move on the surface of the precast beam, there may be situations where they need to cross wet joints or wet seams to reach the surface of other adjacent precast beams. Therefore, the present invention can utilize the crossing unit provided on the execution module and / or auxiliary module to achieve the crossing of wet joints or wet seams to reach the surface of other adjacent precast beams.

[0020] The present invention also discloses a combined high-altitude welding system, comprising: a central control module for generating control signals based on the construction plan, construction site conditions and / or control instructions input by the operator; an execution module for executing welding process operations based on the control signals generated by the central control module; and an auxiliary module for executing welding auxiliary operations based on the control signals generated by the central control module.

[0021] The central control module can drive the execution module and auxiliary module to complete the welding operation in combination and / or drive the execution module or auxiliary module independently to cooperate with the operator to complete the welding operation. When the central control module drives the execution module and auxiliary module to complete the welding operation in combination, the temperature distribution inside the receiver, which is set in the receiver for collecting welding slag by the third monitoring unit of the auxiliary module, can be used to adjust the operating parameters of the execution module.

[0022] According to a preferred embodiment, a receiver comprising a fixed plate and a plurality of flip plates is movably connected to an adjusting rod. When the adjusting rod is fixed, the receiver can reciprocate along a groove opened thereon under external driving action to adjust the relative position of the receiver and the adjusting rod, and / or can rotate around the connection structure between the receiver and the adjusting rod under external driving action so that the receiver completes a partial angle deflection in a specified direction.

[0023] According to a preferred embodiment, when the construction site is a precast beam bridge deck for a bridge project, the second motion unit configured in the execution module and the third motion unit configured in the auxiliary module can be respectively set on both sides of the wet joint or wet seam to be welded, so that the execution module and the auxiliary module can perform corresponding operations at different angles. The execution module and the auxiliary module can cross the wet joint or wet seam through their respective configured crossing units.

[0024] According to a preferred embodiment, the crossing unit includes an extension rod capable of telescoping horizontally and a support rod capable of telescoping vertically, wherein the second and third motion units are capable of moving along the respective extension rods without contacting the surface of the currently located precast beam to move above the adjacent precast beam.

[0025] According to a preferred embodiment, the high-altitude welding system is also equipped with a detection module that is communicatively connected to the central control module. The detection module scans the construction site before and / or after the welding operation to obtain image information related to the target to be welded within the construction site. This allows the central control module to obtain the location information of the area to be welded and / or the welding operation quality score through analysis. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of a preferred embodiment of the combined high-altitude welding system provided by the present invention;

[0027] Figure 2 This is a schematic diagram of the detection module according to a preferred embodiment of the present invention;

[0028] Figure 3 This is a construction schematic diagram of the execution module and auxiliary module of a preferred embodiment of the present invention from one perspective;

[0029] Figure 4 This is a construction schematic diagram of the execution module and auxiliary module of a preferred embodiment of the present invention from another perspective;

[0030] Figure 5 This is a schematic diagram illustrating how the execution module and auxiliary module of a preferred embodiment of the present invention achieve traversal with the assistance of a traversal unit;

[0031] Figure 6 This is a schematic diagram of the structure of a collection unit according to a preferred embodiment of the present invention;

[0032] Figure 7 This is a hardware connection diagram of a preferred embodiment of the combined high-altitude welding system provided by the present invention;

[0033] Figure 8 This is a flowchart of a preferred embodiment of the combined high-altitude welding method provided by the present invention.

[0034] List of reference numerals

[0035] 100: Detection module; 110: First motion unit; 120: First monitoring unit; 200: Execution module; 210: Second motion unit; 220: Operation unit; 221: Mounting bracket; 222: Proximal articulated arm; 223: Distal articulated arm; 224: Transition component; 225: Welding torch; 230: Second monitoring unit; 240: Control unit; 300: Auxiliary module; 310: Third motion unit; 320: Collection unit; 321: Adjusting rod; 322: Receiver; 323: Fixing plate; 324: Flipping plate; 330: Crossing unit; 331: Extension rod; 332: Support rod; 340: Third monitoring unit; 350: Clamping unit; 400: Central control module. Detailed Implementation

[0036] The following is a detailed explanation with reference to the accompanying drawings.

[0037] Example 1

[0038] like Figures 1 to 7As shown, this invention discloses a combined high-altitude welding system, particularly suitable for welding operations during bridge construction. Preferably, precast beams are a common structural component in bridge construction. They are manufactured in a factory environment and then transported to the construction site for assembly and installation. The manufacturing process of precast beams includes the pouring, curing, finishing, and quality inspection of concrete or other materials. By manufacturing in the factory, precast beams can be subject to more rigorous and precise control, ensuring their quality and reliability. Precast beams can withstand greater loads and forces, making the engineering structure more robust and stable. The design and manufacturing of precast beams can be customized according to the specific needs of the project to adapt to different engineering requirements. Compared to traditional on-site construction, precast beams have many advantages. First, they can reduce the time and cost required for on-site construction. Since precast beams are manufactured in the factory, assembly and installation can be carried out more quickly on the construction site, improving project progress. Second, precast beams can reduce reliance on on-site labor, lowering labor costs. Since most of the manufacturing process of precast beams is completed in the factory, the occupation of the construction site and manual operations are reduced, lowering the demand for human resources. In addition, the manufacturing process of precast beams can reduce the generation of construction waste and have a smaller impact on the environment.

[0039] Furthermore, the installation process of precast beams can typically be carried out using a method of first simply supported beams and then continuous beams. This method is a widely used structural form in building engineering. A simply supported beam is a beam constrained by supports at both ends, typically used for short-span bridges. A continuous beam, on the other hand, is formed by connecting multiple simply supported beams through sliding or fixed supports to create a continuous structure. This structural form has many advantages and is suitable for the design of long-span bridges. The design principle of this method is to start with a preliminary design using simply supported beams and then consider adding supports between the beams to form a continuous beam. First, the dimensions and stress conditions of the simply supported beams are determined, and then the type of simply supported beam is selected based on the span and load conditions. Next, the simply supported beams are connected using appropriate support methods to form a continuous beam structure. Simultaneously, the reaction force transmission and sliding deformation at the supports must be considered to ensure the stability and safety of the structure. The structural design of this method requires full consideration of the beam's stress performance and strength requirements. Based on specific design requirements, the cross-sectional shape and dimensions of the beam are determined, and calculations and analyses are performed with reference to relevant specifications and standards. Simultaneously, a stress analysis is necessary, considering factors such as pressure, bending force, and shear force at various locations to ensure the beam can withstand the corresponding loads and moments during use.

[0040] Preferably, when constructing precast beams using the method of first simply supported beams and then continuous beams, the precast beams that have been manufactured in the factory can be arranged side by side at intervals between the same group of piers to form a span. The gap between adjacent precast beams in the same span can form a wet joint, and the gap between adjacent spans on the shared piers can form a wet joint. Typically, a continuous bridge deck can be formed by first welding and casting the wet joint, and then welding and casting the wet joint.

[0041] According to a preferred embodiment, the combined high-altitude welding system of the present invention is applicable to the welding process of wet joints and / or wet seams between precast beams. It includes a detection module 100, an execution module 200, and an auxiliary module 300. The detection module 100, execution module 200, and auxiliary module 300 are all communicatively connected to a central control module 400 to adjust operating parameters based on control signals from the central control module 400. Preferably, the central control module 400 can be mounted on or connected to a user terminal used by the operator, allowing the operator to input control commands and obtain output information through the user terminal. The output information may include real-time operating parameters of each functional module, image information of the welded joint, current task progress, etc., enabling the operator to promptly monitor the welding operation.

[0042] Preferably, such as Figure 2 As shown, the detection module 100 can move within the construction site using the first motion unit 110, allowing the first monitoring unit 120 mounted on the first motion unit 110 to acquire image information related to the bridge deck while moving with the first motion unit 110. Preferably, the image information acquired by the first monitoring unit 120 of the detection module 100 can be sent to the central control module 400, enabling the central control module 400 to generate a corresponding three-dimensional model based on the image information. Preferably, the first motion unit 110 can be configured with several rotors, allowing the detection module 100 to move freely in the air above the construction site, suitable for high-altitude welding situations. Preferably, the first monitoring unit 120 can utilize UAV oblique photography technology to acquire observation data, overcoming the limitation of traditional orthophotos which can only analyze ground features vertically.

[0043] Preferably, the central control module 400 can identify the image information acquired by the first monitoring unit 120 to filter out the areas of wet joints and wet seams, and can determine the location information of the areas to be welded in the generated three-dimensional model. Further, the central control module 400 can determine the work sequence of multiple areas to be welded based on the location information of the areas to be welded in the three-dimensional model and the bridge construction plan. For example, for a bridge construction plan where wet joints are welded and poured first, followed by wet seams, the central control module 400 can assign a relatively earlier work position number to the wet joints and a relatively later work position number to the wet seams, and can plan based on the principle of shortest travel distance.

[0044] Preferably, the central control module 400 can plan the movement route of the execution module 200 according to the work sequence generated by itself and / or input by the operator through the user terminal. The execution module 200 can move along the planned movement route in response to the control signal issued by the central control module 400. During the movement along the planned movement route, the execution module 200 can identify the target to be welded in order to pre-generate corresponding suggested operating parameters.

[0045] Preferably, the execution module 200 may be configured with a second motion unit 210 capable of moving on the surface of the precast beam, so as to move the target to be welded into the operating range of the execution module 200 by moving the second motion unit 210 along the moving path planned by the execution module 200. Preferably, the execution module 200 may also be configured with a control unit 240 and an operation unit 220 signal-connected to the control unit 240, wherein the control unit 240 may be communicatively connected to the central control module 400 to receive control signals (e.g., the moving path planned by the central control module 400) issued by the central control module 400 and drive the second motion unit 210 and / or the operation unit 220 to perform corresponding control operations.

[0046] Preferably, the operating arm of the operating unit 220 can be a six-degree-of-freedom welding robotic arm, wherein the robotic arm is mounted on the second motion unit 210 via a mounting bracket 221, and the robotic arm and the mounting bracket 221 can be pivotally connected. Preferably, one end of the proximal curved arm 222 of the robotic arm can be connected to the mounting bracket 221, and the other end can be connected to the distal curved arm 223, wherein the above connections can be hinged via a pivot to enable the connection of the curved arms of the robotic arm. Preferably, the opposite end of the distal curved arm 223 of the robotic arm connected to the proximal curved arm 222 can be hinged to a transition member 224, wherein a welding torch 225 can be fixedly mounted or detachably mounted on the transition member 224. Furthermore, the transition member 224 can be partially rotated to increase the degree of freedom of movement.

[0047] Preferably, the execution module 200 may be configured with a second monitoring unit 230 to acquire physical data of the weld seam of the target to be welded, so that the control unit 240 can coordinately control the second motion unit 210 and the operation unit 220 to realize task path adjustment planning, welding torch 225 posture generation, and real-time deviation correction. Preferably, the second monitoring unit 230 can be set on the transition member 224 with its centerline parallel to the centerline of the welding torch 225, so that the relative displacement between the two remains constant. Preferably, the second monitoring unit 230 may be configured as a weld seam tracker, and the acquired physical data of the weld seam of the target to be welded may include weld seam three-dimensional trajectory data and weld seam width data. Preferably, the second monitoring unit 230 may be configured with an image acquisition device to acquire image information related to the weld seam of the target to be welded.

[0048] Preferably, when the second monitoring unit 230 acquires the physical data of the weld of the target to be welded (e.g., the reinforcing steel in a wet joint and / or wet seam), it can first acquire the three-dimensional model data and relative position data of the target to be welded that makes up the weld, so that the control unit 240 can generate model information related to the weld in the three-dimensional model. The three-dimensional model can be acquired from the central control module 400, and the three-dimensional model of the central control module 400 is generated based on the image information acquired by the detection module 100. Furthermore, when the control unit 240 acquires the three-dimensional model from the central control module 400, it can load only a local three-dimensional model to improve data processing efficiency. Specifically, the control unit 240 can acquire a three-dimensional model containing a local area of ​​the wet joint or wet seam where the target to be welded is located.

[0049] Preferably, when the operation unit 220 is ready to perform the welding process operation on the weld seam of the target to be welded, the second monitoring unit 230 provided on the transition member 224 can be used to detect the real weld seam information, so as to judge the accuracy of the weld seam related model generated by the control unit 240 by comparing it with the corresponding three-dimensional model.

[0050] Preferably, the control unit 240 can solve for the actual three-dimensional information of the weld seam of the target to be welded from the image information acquired by the second monitoring unit 230 by establishing multiple coordinate systems. These coordinate systems may include a world coordinate system, a camera coordinate system, an image coordinate system, and a focal plane coordinate system. Further, the control unit 240 can preprocess the image information acquired by the second monitoring unit 230 and extract target feature points to obtain coordinate information related to the target feature points in the image information. By matching the target feature points in multiple images taken from different positions and / or angles, the position information in the world coordinate system can be calculated. Preferably, the control unit 240 can match the calculated coordinate information of the actual weld seam in the world coordinate system with an existing welding process rule library to select the optimal welding scheme. Further, the control unit 240 can generate corresponding control signals based on the selected welding scheme and send them to the operation unit 220 and / or the second motion unit 210 to execute the welding process operation.

[0051] Preferably, the second monitoring unit 230 may also include various devices for collecting parameter information of the welding process, such as current sensors and voltage sensors, so that the control unit 240 can adjust the operation unit 220 and / or the second motion unit 210 according to the real-time welding situation.

[0052] Preferably, the auxiliary module 300 may include a third motion unit 310 and a collection unit 320 disposed on the third motion unit 310, wherein the third motion unit 310 can move and stop on the surface of the precast beam to adjust the position of the collection unit 320. Preferably, as Figure 6As shown, the collection unit 320 may include an adjusting rod 321 and a receiver 322 for collecting welding slag spatter from the welding process. The adjusting rod 321 may be movably connected to the receiver 322 so that their relative positional relationship is adjustable. Preferably, the adjusting rod 321 may have multiple adjustment dimensions so that the receiver 322 can be adjusted in the horizontal and / or vertical directions. The auxiliary module 300 may determine the adjustment scheme of the adjusting rod 321 based on the three-dimensional model generated by the central control module 400 to avoid collisions between the adjusting rod 321 and / or the receiver 322 and other building structures. Furthermore, the receiver 322 may be provided with a groove and equipped with a motor, so that when the adjusting rod 321 is fixed in position by the third motion unit 310, the receiver 322 can reciprocate along the opening direction of the groove under the drive of the motor, so that the receiver 322 can be set in a manner that is partially offset relative to the adjusting rod 321, thereby adapting to various welding situations (e.g., entering from the side into a space that is difficult to enter directly from the front). Preferably, the connection structure between the receiver 322 and the adjusting rod 321 may include a spherical rotating member, so that by driving the spherical rotating member to complete a partial angle rotation in a specified direction, the receiver 322 can still maintain a relatively horizontal position even if the third motion unit 310 is partially offset due to the unevenness of the precast beam surface, thus preventing the welding slag falling into the receiver 322 from rolling and colliding within the receiver 322. Preferably, the connection structure between the receiver 322 and the adjusting rod 321 is made of a high-strength material to improve the stability and lifespan of the collection unit 320.

[0053] Preferably, the receiver 322 may include a fixed plate 323 and flip plates 324 disposed on both sides of the fixed plate 323. The flip plates 324 are rotatable about the axis of their connection with the fixed plate 323 to expand the area of ​​the fixed plate 323, thereby collecting as much spattered weld slag as possible into the receiver 322. Preferably, when the flip plates 324 are not rotated, the width of the receiver 322 is approximately equal to the width of the fixed plate 323, and both are smaller than the width of the wet joint and / or wet seam. Further, the direction in which the flip plates 324 expand the area of ​​the fixed plate 323 is perpendicular to the opening direction (i.e., the length direction) of the wet joint and / or wet seam. In other words, the flip plates 324 disposed on both sides of the fixed plate 323 can be flipped toward the precast beams on both sides of the wet joint and / or wet seam, so that the rotated flip plates 324 and the fixed plate 323 can form a roughly flat collection surface, and the width of the expanded collection surface is greater than the width of the wet joint and / or wet seam. This configuration allows the receiver 322 to pass freely through wet joints and / or wet seams in the tightened state, and after reaching the target to be welded, it can be switched to the unfolded state to form a relatively larger collection surface, thereby collecting as much spatter as possible.

[0054] Preferably, when the central control module 400 drives the execution module 200 and the auxiliary module 300, the second motion unit 210 and the third motion unit 310 can be placed on the surfaces of the precast beams located on both sides of the wet joint or wet seam to be welded, so that the execution module 200 and the auxiliary module 300 can operate from different angles, thereby avoiding conflicts in the operation paths. Preferably, when the second motion unit 210 and the third motion unit 310 move on the surface of the precast beam, there may be situations where they need to cross the wet joint or wet seam to reach the surface of other adjacent precast beams. Therefore, if... Figure 5 As shown, the present invention may include a crossing unit 330 on the execution module 200 and / or auxiliary module 300 to achieve crossing of wet joints or wet seams. Preferably, the crossing unit 330 may include a linkage structure composed of an extension rod 331 and a support rod 332, wherein the extension rod 331 can extend and retract in the horizontal direction, and the support rod 332 can extend and retract in the vertical direction. For example, when the execution module 200 needs to cross a wet joint or wet seam, the second motion unit 210 first moves to the edge of the wet joint or wet seam to be crossed. The extension rod 331 of its crossing unit 330 extends above the adjacent precast beam along a direction that is approximately perpendicular to the length of the wet joint or wet seam (i.e., approximately parallel to the width direction of the wet joint or wet seam). A plurality of support rods 332 on the extension rod 331 extend vertically to abut against the surface of the current precast beam and the surface of the adjacent precast beam. The support rods 332 continue to extend to lift the second motion unit 210. The second motion unit 210, which is not in contact with the surface of the current precast beam, can be transmitted along the extension rod 331 to the top of the adjacent precast beam and contact the surface of the adjacent precast beam after the support rods 332 retract, so as to complete the crossing of the wet joint or wet seam. For example, when the auxiliary module 300 needs to cross a wet joint or wet seam, the third motion unit 310 first moves to the edge of the wet joint or wet seam to be crossed. The extension rod 331 of its crossing unit 330 extends above the adjacent precast beam along a direction that is approximately perpendicular to the length of the wet joint or wet seam (i.e., approximately parallel to the width direction of the wet joint or wet seam). A plurality of support rods 332 on the extension rod 331 extend vertically to abut against the surface of the current precast beam and the surface of the adjacent precast beam. The support rods 332 continue to extend to lift the third motion unit 310. The third motion unit 310, which does not contact the surface of the current precast beam, can be transmitted along the extension rod 331 to the top of the adjacent precast beam and contact the surface of the adjacent precast beam after the support rods 332 retract, so as to complete the crossing of the wet joint or wet seam. Preferably, when the extension rod 331 of the traversing unit 330 extends above the adjacent precast beam, at least a portion of the space is reserved to allow the corresponding moving unit to contact the surface of the adjacent precast beam.

[0055] Preferably, the auxiliary module 300 may also be provided with a clamping unit 350 to temporarily fix relatively more mobile targets (such as the U-shaped steel bars to be welded) among the welding targets, so that the execution module 200 can complete the welding process operation more smoothly.

[0056] Preferably, the auxiliary module 300 may also be provided with a counterweight unit, wherein the counterweight unit may be provided on the third motion unit 310, and the auxiliary module 300 may be prevented from tipping over by adjusting the position of the counterweight unit on the third motion unit 310.

[0057] Preferably, the second motion unit 210 and the third motion unit 310 can move synchronously or asynchronously depending on the construction site conditions, as long as the slag interception rate is within a preset range. Preferably, the operating parameters of the operation unit 220 of the execution module 200 of the present invention can be controlled not only by the monitoring data acquired by the second monitoring unit 230, but also by the monitoring data acquired by the third monitoring unit 340 set in the auxiliary module 300. Preferably, the auxiliary module 300 can be independently equipped with a control unit 240 or share a control unit 240 with the execution module 200.

[0058] Preferably, the third monitoring unit 340 can be configured as a plurality of temperature sensors arranged in an array on the inner surface of the receiver 322 to obtain the temperature value of the weld slag falling onto the inner surface of the receiver 322. Preferably, the arrangement density of the third monitoring unit 340 on the inner surface of the receiver 322 can be determined according to the aspect ratio of the receiver 322 in its unfolded state, wherein the arrangement density can be characterized by a set of values ​​for the lateral spacing and the longitudinal spacing. Further, the third monitoring unit 340 can feed back the real-time temperature values ​​obtained by each temperature sensor to the control unit 240, so that the control unit 240 can generate a temperature distribution image of the inner surface of the receiver 322 at various times, wherein the temperature sensors in the receiver 322 can periodically collect real-time temperature data and send the temperature distribution in the receiver 322 at the same time to the control unit 240 in the form of slices, so that the control unit 240 can generate a temperature distribution image at the corresponding time according to the change of the temperature distribution in the receiver 322 over time. Preferably, the control unit 240 can determine the increment and distribution location of the welding slag falling based on the temperature distribution image at each time point, so as to simulate the evolution process of the welding slag falling on the inner surface of the receiver 322, thereby determining the accuracy of the welding process operation.

[0059] Preferably, the control unit 240 can adjust the operating parameters of the operation unit 220 of the execution module 200 based on the data information obtained by the third monitoring unit 340. For example, when the control unit 240 determines that the increase in the amount of welding slag falling in the receiver 322 within a unit time exceeds a set threshold and / or the increase in the amount of welding slag falling in the receiver 322 within a unit area exceeds a set threshold, the control unit 240 can adjust the operating parameters of the operation unit 220 of the execution module 200. The adjustment method may include changing the welding angle, controlling the current and voltage, and adjusting the welding speed.

[0060] Preferably, when analyzing the temperature distribution within the receiver 322 over time, the control unit 240 can introduce or exclude certain factors to improve the processing and recognition accuracy of the temperature distribution image. Preferably, the introduced factors may include real-time environmental factors, such as ambient temperature and humidity, so that the control unit 240 can consider the impact of natural cooling on the temperature distribution image. The control unit 240 can determine the natural cooling coefficient at the current moment based on real-time environmental factors to predict the temperature distribution image at the next moment when it is unaffected by newly fallen welding slag. Preferably, the excluded factors may include any factors that interfere with the calculation of the welding slag drop increment. For example, if welding slag that has already been statistically analyzed and has deviated from its original landing point due to collision, tilting, or other reasons is captured again by temperature sensors at other locations, it may cause duplicate calculations of the welding slag drop increment. Furthermore, the control unit 240 can calculate the approximate temperature range of the welding slag generated during the welding process as it falls onto the inner surface of the receiver 322 based on the operating parameters of the operation unit 220 of the execution module 200. This allows the control unit 240 to determine whether the temperature value at a newly added temperature surge point is within the aforementioned temperature range when the temperature sensor installed on the receiver 322 detects such a point. If the temperature value at that point is within the aforementioned temperature range, it can be identified as newly fallen welding slag; conversely, if the temperature value at that point is not within the aforementioned temperature range, it can be identified as non-newly fallen welding slag (i.e., it may be other interfering substances).

[0061] Preferably, when the execution module 200 performs welding operations, especially when it performs welding operations in cooperation with the auxiliary module 300, the central control module 400 can drive the detection module 100 to continuously or intermittently acquire image information of the target to be welded and its surroundings. This allows the central control module, upon receiving the image information acquired by the detection module 100, to determine if there is a deviation in the welding process and to instruct the execution module 200 and / or the auxiliary module 300 to adjust their operating parameters to correct the welding operation. Preferably, the image information acquired by the detection module 100 during the welding process may include image slices characterizing the welding operation of the execution module 200 and / or the welding auxiliary operation of the auxiliary module 300, to generate an operation decomposition diagram arranged according to a time sequence. This allows the central control module 400 to determine whether there is a deviation in the welding process by comparing the operation decomposition diagram with standard operating data. Furthermore, the central control module 400 can combine and compare image slices of the execution module 200 performing welding process operations and the auxiliary module 300 performing welding auxiliary operations at the same time point based on time series, to determine the degree of cooperation between the execution module 200 and the auxiliary module 300, and can adjust the welding process operations and / or welding auxiliary operations when the degree of cooperation is low. Preferably, the image information acquired by the detection module 100 during the welding process may include weld slag spatter images. The central control module 400 can generate a weld slag coverage area based on the weld slag spatter image and send it to the control unit 240, so that the control unit 240 can further determine the deviation of the welding process by combining the data information acquired by the third monitoring unit 340 with the weld slag coverage area sent by the central control module 400 while processing the data information acquired by the third monitoring unit 340. This allows the execution module 200 and / or the auxiliary module 300 to adjust their operating parameters more accurately, thereby improving welding quality and optimizing weld slag collection. Furthermore, when generating the slag coverage area, the central control module 400 can determine the slag obstruction situation based on the real-time position of the auxiliary module 300 and the current configuration of the receiver 322. The central control module 400 or the control unit 240 can determine whether it is necessary to adjust the operating parameters of the execution module 200 and / or the auxiliary module 300 based on the proportion of the slag coverage area that exceeds the collection range of the receiver 322.

[0062] Preferably, after the execution module 200 completes the welding task of the target to be welded in a region, the central control module 400 can drive the detection module 100 to perform a second scan of the region after a preset interval. The detection module 100 can fly in a manner that is closer to the wet joint and / or wet seam than the first scan to obtain a clearer weld image. This allows the central control module 400 to analyze the weld image and score the quality of the welding operation based on preset evaluation criteria, so as to feed back the weld image to the operator's user terminal.

[0063] Example 2

[0064] This embodiment is a further improvement on embodiment 1, and repeated content will not be described again.

[0065] like Figure 8 As shown, the present invention also discloses a combined high-altitude welding method, which can employ the combined high-altitude welding system as described in Example 1. Preferably, it includes one or more of the following steps:

[0066] Before performing welding operations, the detection module 100 scans the construction site to obtain image information related to the target to be welded within the construction site, thereby analyzing the location information of the area to be welded.

[0067] The drive execution module 200 and the auxiliary module 300 work together to complete the welding operation and / or the drive execution module 200 or the auxiliary module 300 work independently to assist the operator in completing the welding operation;

[0068] After the welding operation is performed, the detection module 100 scans the construction site to obtain image information related to the target to be welded, thereby analyzing and obtaining a score for the quality of the welding operation.

[0069] Preferably, the execution module 200 for performing welding process operations and the auxiliary module 300 for performing welding auxiliary operations can complete the welding operation in a cross-control manner.

[0070] It should be noted that the specific embodiments described above are exemplary. Those skilled in the art can devise various solutions inspired by the disclosure of this invention, and these solutions all fall within the scope of this invention and its protection. Those skilled in the art should understand that this specification and its accompanying drawings are illustrative and do not constitute a limitation on the claims. The scope of protection of this invention is defined by the claims and their equivalents. This specification contains multiple inventive concepts; phrases such as "preferred" or "according to a preferred embodiment" indicate that the corresponding paragraph discloses an independent concept. The applicant reserves the right to file divisional applications based on each inventive concept. Throughout the text, the feature introduced by "preferred" is only an optional mode and should not be construed as mandatory. Therefore, the applicant reserves the right to abandon or delete relevant preferred features at any time.

Claims

1. A combined high-altitude welding method, characterized in that, Includes the following steps: Before performing welding operations, the construction site is scanned using a detection module (100) to obtain image information related to the target to be welded within the construction site, thereby analyzing the location information of the area to be welded. The drive execution module (200) and the auxiliary module (300) can work together to complete the welding operation in combination or drive the execution module (200) and the auxiliary module (300) independently to cooperate with the operator to complete the welding operation. After the welding operation is performed, the detection module (100) scans the construction site to obtain image information related to the target to be welded, thereby analyzing and obtaining a score for the quality of the welding operation. The execution module (200) for performing welding process operations and the auxiliary module (300) for performing welding auxiliary operations can complete the welding operation in a cross-control manner; The auxiliary module (300) includes a third motion unit (310) and a collection unit (320) disposed on the third motion unit (310). The collection unit (320) includes an adjusting rod (321) and a receiver (322) for collecting welding slag spattered during the welding process. When the central control module (400) drives the execution module (200) and the auxiliary module (300) to complete the welding operation in combination, the temperature distribution in the receiver (322) obtained by the third monitoring unit (340) set in the receiver (322) for collecting welding slag by the auxiliary module (300) can be used to adjust the operating parameters of the execution module (200).

2. The high-altitude welding method according to claim 1, characterized in that, The receiver (322), comprising a fixed plate (323) and a plurality of flip plates (324), is movably connected to the adjusting rod (321) so that when the adjusting rod (321) is fixed, the receiver (322) can reciprocate along a groove opened thereon under external driving action to adjust the relative position of the receiver (322) and the adjusting rod (321), and / or can rotate around the connection structure of the receiver (322) and the adjusting rod (321) under external driving action so that the receiver (322) completes a partial angle deflection in a specified direction.

3. The high-altitude welding method according to any one of claims 1 or 2, characterized in that, When the construction site is a precast beam bridge deck for a bridge project, the second motion unit (210) configured in the execution module (200) and the third motion unit (310) configured in the auxiliary module (300) are respectively set on both sides of the wet joint or wet seam to be welded, so that the execution module (200) and the auxiliary module (300) can perform corresponding operations at different angles.

4. The high-altitude welding method according to claim 3, characterized in that, When the execution module (200) and / or the auxiliary module (300) need to cross wet joints or wet seams, they are accomplished by using crossing units (330) configured on the execution module (200) and / or the auxiliary module (300). The crossing unit (330) includes an extension rod (331) that can extend and retract in the horizontal direction and a support rod (332) that can extend and retract in the vertical direction. The second motion unit (210) and the third motion unit (310) can move along the corresponding extension rod (331) without contacting the surface of the currently located precast beam to move above the adjacent precast beam.

5. A combined high-altitude welding system, characterized in that, It includes: The central control module (400) is used to generate control signals based on the construction plan, the construction site conditions, and / or the control instructions input by the operators; The execution module (200) is used to execute welding process operations according to the control signals generated by the central control module (400); The auxiliary module (300) is used to perform welding auxiliary operations according to the control signals generated by the central control module (400). The auxiliary module (300) includes a third motion unit (310) and a collection unit (320) disposed on the third motion unit (310). The collection unit (320) includes an adjusting rod (321) and a receiver (322) for collecting welding slag spattered during the welding process. The central control module (400) can drive the execution module (200) and the auxiliary module (300) to complete the welding operation in combination or drive the execution module (200) and the auxiliary module (300) independently to cooperate with the operator to complete the welding operation. When the central control module (400) drives the execution module (200) and the auxiliary module (300) to complete the welding operation in combination, the temperature distribution in the receiver (322) set by the third monitoring unit (340) in the receiver (322) for collecting welding slag in the auxiliary module (300) can be used to adjust the operating parameters of the execution module (200).

6. The high-altitude welding system according to claim 5, characterized in that, The receiver (322), which includes a fixed plate (323) and multiple flip plates (324), can be movably connected to an adjusting rod (321). When the adjusting rod (321) is fixed, the receiver (322) can reciprocate along a groove opened thereon under external driving action to adjust the relative position of the receiver (322) and the adjusting rod (321), and / or can rotate around the connection structure of the receiver (322) and the adjusting rod (321) under external driving action so that the receiver (322) completes a partial angle deflection in a specified direction.

7. The high-altitude welding system according to claim 5 or 6, characterized in that, When the construction site is a precast beam bridge deck for a bridge project, the second motion unit (210) configured in the execution module (200) and the third motion unit (310) configured in the auxiliary module (300) can be respectively set on both sides of the wet joint or wet seam to be welded, so that the execution module (200) and the auxiliary module (300) can perform corresponding operations at different angles. The execution module (200) and the auxiliary module (300) can cross the wet joint or wet seam through their respective crossover units (330).

8. The high-altitude welding system according to claim 7, characterized in that, The crossing unit (330) includes an extension rod (331) that can extend and retract in the horizontal direction and a support rod (332) that can extend and retract in the vertical direction, wherein the second motion unit (210) and the third motion unit (310) can move along the corresponding extension rod (331) without contacting the surface of the currently located precast beam to move above the adjacent precast beam.

9. The high-altitude welding system according to claim 8, characterized in that, The high-altitude welding system is also equipped with a detection module (100) that is communicatively connected to the central control module (400). The detection module (100) scans the construction site before and / or after the welding operation to obtain image information related to the target to be welded within the construction site, so that the central control module (400) can obtain the location information of the area to be welded and / or the score of the welding operation quality through analysis.

Images