A double-line automatic welding line for New Jersey guardrails and its automatic welding process

Abstract

This invention discloses a dual-line automatic welding line for New Jersey fencing and its automatic welding process. The automatic welding line includes a rebar cage fixing bracket, a traveling track, and a welding robot. The traveling track and welding robot are respectively arranged on both sides of the rebar cage fixing bracket. The welding robot has a welding head assembly and is movably mounted on the traveling track. The rebar cage fixing bracket has a positioning area for positioning the New Jersey fencing rebar cage. A first positioning structure and a second positioning structure are provided in the positioning area. The first positioning structure is used to position several stirrups of the New Jersey fencing rebar cage, and the second positioning structure is used to position several horizontal ribs. This invention uses a dual-line traveling welding robot to automatically weld the welding points on both sides of the New Jersey fencing rebar cage, improving welding efficiency. High-precision custom-made slotted strips are laser-cut, and pneumatic vises are used to position the stirrups and horizontal ribs, fixing them in preset positions with small precision errors and uniform, high-quality welding.

Description

Technical Field

[0001] This invention relates to the field of road and bridge engineering production equipment and process technology, and in particular to a double-line New Jersey guardrail automatic welding line and its automatic welding process. Background Technology

[0002] New Jersey guardrails are wall-type guardrails with a specific cross-sectional shape. They are widely used due to their numerous engineering advantages and are a very common guardrail product in modern road and bridge engineering. New Jersey guardrails are actually reinforced concrete products. Because of their widespread use in modern road and bridge engineering, improvements to the production equipment and processes for New Jersey guardrails can help reduce project costs for relevant construction companies and enhance their overall competitiveness. Specifically, the production process of New Jersey guardrails mainly includes two parts: the binding and welding of the reinforcing cage and the pouring of concrete. For the binding and welding of the reinforcing cage, since there are many welding points, inaccurate positioning or incomplete welding will affect the final product quality of the New Jersey guardrail. Manual welding is obviously labor-intensive, inefficient, and costly. Therefore, to improve production efficiency and quality, adopting an automated welding line is the inevitable choice. However, solving the positioning and welding problems in the process of binding and welding the rebar cage is clearly the key challenge in realizing the automated welding line and welding process for the New Jersey fence. Existing technologies lack relevant mature solutions to achieve the above objectives. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a dual-line automatic welding line for New Jersey guardrails. The technical solution of this invention is as follows:

[0004] A double-line automatic welding line for New Jersey guardrails includes a rebar cage fixing bracket, a traveling track, and a welding robot. The traveling track and welding robot are respectively arranged on both sides of the rebar cage fixing bracket. The welding robot has a welding head assembly and is movably mounted on the traveling track. The rebar cage fixing bracket has a positioning area for positioning the New Jersey guardrail rebar cage. A first positioning structure and a second positioning structure are provided in the positioning area. The first positioning structure is used to position several stirrups of the New Jersey guardrail rebar cage, and the second positioning structure is used to position several transverse bars of the New Jersey guardrail rebar cage.

[0005] As a further explanation of the present invention, the first positioning structure includes a plurality of dimensional strips, and a plurality of stirrup positioning grooves are spaced apart on the dimensional strips.

[0006] Furthermore, the second positioning structure includes a plurality of finger cylinders with front-end grippers, the finger cylinders corresponding to a plurality of horizontal ribs of the New Jersey guardrail steel cage.

[0007] Furthermore, the steel cage fixing bracket includes several fixed plates and several movable plates. The movable plates are slidably mounted on the fixed plates. A movable plate driving mechanism is provided between the fixed plates and the movable plates. The movable plate driving mechanism is used to drive the opening and closing movement of the movable plates. The fixed plates and the movable plates are respectively provided with the contour notches of the New Jersey fence steel cage. The openings of the contour notches face upwards, and the opening width of the contour notches is relatively large.

[0008] Furthermore, the movable plate driving mechanism includes a movable plate opening and closing driving cylinder and a movable plate slide rail. The movable plate opening and closing driving cylinder is mounted and fixed on the fixed plate and is used to drive the movable plate to slide back and forth along the movable plate slide rail.

[0009] Furthermore, the lower part of the steel cage fixing bracket is provided with several longitudinal positioning plates, and several longitudinal grooves are formed between the longitudinal positioning plates. The fixing plate is installed in the longitudinal grooves. The upper two ends of the fixing plate are provided with transverse grooves, and transverse positioning plates are installed in the transverse grooves.

[0010] Furthermore, the fixing plate is provided with a strip mounting groove, and the sized strip is installed in the strip mounting groove through a strip adjustment mechanism.

[0011] Furthermore, the strip adjustment mechanism includes a top screw rod and a top screw seat, the top screw seat is fixed on the fixed plate, and the top screw rod is mounted on the top screw seat with one end connected to the strip of the specified size.

[0012] Furthermore, ventilation pipes are provided on both sides of the steel cage fixing bracket, and the finger cylinder and the movable plate opening and closing drive cylinder are connected to the ventilation pipes.

[0013] On the other hand, the present invention also provides an automatic welding process for a double-line New Jersey guardrail, comprising the following steps:

[0014] S1, to process the steel bars into stirrups and cross bars for the New Jersey fence steel cage;

[0015] S2, the stirrups and crossbars are manually placed at their corresponding positions in the positioning area of ​​the steel cage fixing bracket. The stirrups are positioned by the first positioning structure and the crossbars are positioned by the second positioning structure.

[0016] S3, start the equipment, and the relevant fastening components will tighten the stirrups and cross bars;

[0017] S4, Welding begins. The welding robot moves along its tracks from both sides of the steel cage support, automatically welding each point of the stirrups and crossbars according to the control program until the entire New Jersey fence steel cage is welded.

[0018] S5. After welding is completed, the relevant fastening components loosen their fastening of the stirrups and crossbars, and the welded New Jersey fence steel cage is removed as a whole.

[0019] The beneficial effects of this invention are:

[0020] 1. It can be operated by a single person. The welding robot moves in a double line and automatically welds the welding points on both sides of the New Jersey guardrail rebar cage. The processing time for each New Jersey guardrail rebar cage is 4-5 minutes, which can improve the efficiency by 2 times compared with manual production, and greatly improve the welding efficiency of New Jersey guardrail rebar cage.

[0021] 2. High-precision custom-made slot strips are cut using laser cutting, and the hoops and horizontal bars are positioned using pneumatic vises and fixed in the preset positions, with the accuracy error controlled within the millimeter level;

[0022] 3. Through pre-programming, the welding robot automatically adjusts parameters such as the position of the robotic arm, dwell time, and current to achieve orderly welding and uniform and high-quality welding.

[0023] 4. The automated welding production line reduces the space required for the site, effectively reducing the area occupied by the rebar tying area while ensuring production capacity in New Jersey, which aligns with the concept of green and environmentally friendly construction. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure layout of the double-line New Jersey guardrail automatic welding line of the present invention;

[0025] Figure 2 This is a schematic diagram of the overall structure of the steel cage fixing bracket according to an embodiment of the present invention;

[0026] Figure 3 This is a partial structural illustration of the steel cage fixing bracket in an embodiment of the present invention. Figure 1 ;

[0027] Figure 4 This is a partial structural illustration of the steel cage fixing bracket in an embodiment of the present invention. Figure 2 ;

[0028] Figure 5 This is a diagram showing the distribution of weld points in the steel reinforcement cage of the New Jersey guardrail according to the present invention;

[0029] Figure 6 This is a flowchart of the automatic welding process for the double-line New Jersey guardrail of the present invention.

[0030] Reference numerals in the attached drawings: 1. Rebar cage fixing bracket; 101. Fixing plate; 102. Movable plate; 2. Walking track; 3. Welding robot; 301. Welding head assembly; 4. Stirrup; 5. Dimension strip; 6. Stirrup positioning groove; 601. Finger cylinder; 7. Gripper; 701. Movable plate opening and closing drive cylinder; 8. Movable plate slide rail; 9. Longitudinal positioning plate; 10. Transverse positioning plate; 11. Strip mounting groove; 12. Top screw rod; 13. Top screw seat; 14. Ventilation pipe; 15. Detailed Implementation

[0031] Example:

[0032] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0033] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0034] As attached Figure 1-5 As shown, this embodiment of a double-line automatic welding line for New Jersey guardrails includes a rebar cage fixing bracket 1, a traveling track 2, and a welding robot 3. The traveling track 2 and the welding robot 3 are respectively arranged on both sides of the rebar cage fixing bracket 1. The welding robot 3 has a welding head assembly 301 and is movably arranged on the traveling track 2. The rebar cage fixing bracket 1 has a positioning area for positioning and placing the New Jersey guardrail rebar cage. The positioning area is provided with a first positioning structure and a second positioning structure. The first positioning structure is used to position a plurality of stirrups 4 of the New Jersey guardrail rebar cage, and the second positioning structure is used to position a plurality of transverse bars 5 of the New Jersey guardrail rebar cage.

[0035] The dual-line automatic welding line for New Jersey guardrails of this invention employs a dual-line movement of welding robots 3, enabling automatic welding of the two sides of the New Jersey guardrail rebar cage. Each New Jersey guardrail rebar cage is processed in 4-5 minutes, doubling the efficiency compared to manual production and significantly improving welding efficiency. The first and second positioning structures position the stirrups 4 and horizontal bars, fixing them in preset positions, thus controlling the welding precision error of the New Jersey guardrail rebar cage to the millimeter level. Through pre-programming, the welding robot 3 automatically adjusts parameters such as the robotic arm position, dwell time, and current, achieving orderly welding with uniform and high-quality welds. The automated welding production line reduces space requirements, effectively minimizing the area occupied by the rebar binding area while maintaining production capacity, aligning with green and environmentally friendly construction principles.

[0036] See the appendix for details. Figure 2-4 As shown, in this embodiment, the first positioning structure includes several size strips 6, and several stirrup positioning grooves 601 are spaced apart on the size strips 6. The stirrup positioning grooves 601 on the size strips 6 can be formed by laser cutting to improve the positioning accuracy of the stirrups 4 and achieve the control of the above-mentioned millimeter-level error accuracy. In this way, several stirrups 4 required for a New Jersey fence steel cage can be precisely assembled and fixed in the positioning area of ​​the steel cage fixing bracket 1 to achieve positioning cooperation with the horizontal bars 5.

[0037] As mentioned above, the New Jersey guardrail rebar cage also includes the positioning of the transverse reinforcing bars 5. Therefore, in this embodiment, see Appendix [reference needed]. Figure 2-4 As shown, the second positioning structure includes several finger cylinders 7 with front-end grippers 701. The finger cylinders 7 are set corresponding to several horizontal bars 5 of the New Jersey guardrail steel cage. That is, a set of finger cylinders 7 is set in the horizontal direction corresponding to each horizontal bar 5. When the horizontal bar 5 is assembled, the finger cylinders 7 are in the open state and can be inserted into the horizontal bar 5. Before starting welding and during automatic welding, the finger cylinders 7 close to fix each horizontal bar 5 in a predetermined horizontal position, that is, to maintain relative tightness and fixation with the stirrups 4, so as to ensure welding quality.

[0038] In this embodiment, the rebar cage fixing bracket 1 includes several fixed plates 101 and several movable plates 102. The movable plates 102 are slidably mounted on the fixed plates 101. A movable plate driving mechanism is provided between the fixed plates 101 and the movable plates 102 to drive the opening and closing movement of the movable plates 102. Both the fixed plates 101 and the movable plates 102 are provided with corresponding contoured notches for the New Jersey fence rebar cage. The openings of the contoured notches face upwards, and the width of the opening ends of the contoured notches is relatively large. Thus, during assembly, the movable plates 102 can be opened, and all the required stirrups 4 and transverse bars 5 for the New Jersey fence rebar cage can be placed on the rebar cage fixing bracket 1 before closing and securing them to ensure effective welding connection. After welding, the movable plates 102 are opened again, and the welded New Jersey fence rebar cage is removed as a whole from the rebar cage fixing bracket 1 using a lifting device, facilitating transportation and saving loading and unloading time on the double-line automatic welding line for New Jersey fences.

[0039] For details, please see the appendix. Figure 4 As shown, the movable plate driving mechanism includes a movable plate opening and closing driving cylinder 8 and a movable plate slide rail 9. The movable plate opening and closing driving cylinder 8 is mounted and fixed on the fixed plate 101 and is used to drive the movable plate 102 to slide back and forth along the movable plate slide rail 9. When it is necessary to open the movable plate 102, the movable plate 102 can be driven to move outwards to perform a loading operation by means of the movable plate opening and closing driving cylinder 8; when it is necessary to close the movable plate 102, the movable plate 102 can be driven to move inwards to perform a unloading operation by means of the movable plate opening and closing driving cylinder 8.

[0040] In this embodiment, the lower part of the rebar cage fixing bracket 1 is provided with several longitudinal positioning plates 10, and several longitudinal grooves are formed between the longitudinal positioning plates 10. The fixing plate 101 is installed in the longitudinal grooves. The upper two ends of the fixing plate 101 are provided with transverse grooves, and transverse positioning plates 11 are installed in the transverse grooves. That is, in this embodiment, the lower end of the fixing plate 101 is fixed by the longitudinal positioning plates 10, and the upper end of the fixing plate 101 is fixed by the transverse positioning plates 11. In this way, the several fixing plates 101 included in the rebar cage fixing bracket 1 are positioned with each other and form a whole. The structure of this embodiment is conducive to the rapid assembly and position adjustment of the fixing plate 101, thereby ensuring the positioning accuracy of the stirrups 4 and the transverse bars 5, and ensuring the welding accuracy of the New Jersey fence rebar cage.

[0041] In a preferred embodiment, the fixing plate 101 of this embodiment is provided with a strip mounting groove 12. The sized strip 6 is installed in the strip mounting groove 12 through a strip adjustment mechanism. In this way, the fixed position of the sized strip 6 can be finely adjusted and kept fixed to ensure its positioning function for the stirrup 4 and to ensure product quality. For details, please refer to the appendix. Figure 3 As shown, the strip adjustment mechanism of this embodiment includes a top screw rod 13 and a top screw seat 14. The top screw seat 14 is fixed on the fixed plate 101. The top screw rod 13 is installed on the top screw seat 14 and one end is connected to the size strip 6. By adjusting the top screw rod 13, the position of the size strip 6 connected to it can be adjusted to achieve the above adjustment effect.

[0042] In this embodiment, see Appendix Figure 2 As shown, in this embodiment, ventilation pipes 15 are provided on both sides of the steel cage fixing bracket 1. The finger cylinder 7 and the movable plate opening and closing drive cylinder 8 are connected to the ventilation pipes 15. Through the ventilation pipes 15, the drive device including the finger cylinder 7 and the movable plate opening and closing drive cylinder 8 can be connected to the drive air source. On the other hand, the related pipelines can be effectively protected to avoid damage from the high-temperature sparks falling during the automatic welding process of the welding robot 3, thus ensuring the safe and effective operation of the double-line New Jersey fence automatic welding line.

[0043] Based on the above-described double-line New Jersey fence automatic welding line structure design of the present invention, which is easy to understand, please refer to the appendix. Figure 6 As shown, the automatic welding process for the double-line New Jersey guardrail of the present invention specifically includes the following steps:

[0044] S1, the steel bars are processed into stirrups 4 and transverse bars 5 of the New Jersey fence steel cage;

[0045] S2, the stirrups 4 and the transverse bars 5 are manually placed at the corresponding positions in the positioning area of ​​the steel cage fixing bracket 1. The stirrups 4 are positioned by the first positioning structure and the transverse bars 5 are positioned by the second positioning structure.

[0046] S3, start the equipment, and the relevant fastening components will tighten the stirrups 4 and transverse bars 5;

[0047] S4, Welding begins. The welding robot 3 moves along the walking track 2 from both sides of the steel cage fixing bracket 1, automatically welding each welding point of the stirrups 4 and transverse bars 5 according to the control program, until the welding of the entire New Jersey fence steel cage is completed.

[0048] S5. After welding is completed, the relevant fastening components loosen their fastening of the stirrups 4 and the transverse bars 5, and the welded New Jersey fence steel cage is removed as a whole.

[0049] The above description only illustrates preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. The present invention is not limited to the above embodiments, and variations in its specific structure are permitted. In short, all variations made within the scope of the independent claims of the present invention are within the scope of protection of the present invention.

Claims

1. A double-line automatic welding line for New Jersey guardrails, characterized in that: The system includes a rebar cage fixing bracket, a traveling track, and a welding robot. The traveling track and the welding robot are respectively arranged on both sides of the rebar cage fixing bracket. The welding robot has a welding head assembly and is movably mounted on the traveling track. The rebar cage fixing bracket has a positioning area for positioning and placing the New Jersey fence rebar cage. The positioning area is provided with a first positioning structure and a second positioning structure. The first positioning structure is used to position several stirrups of the New Jersey fence rebar cage, and the second positioning structure is used to position several transverse bars of the New Jersey fence rebar cage. The first positioning structure includes several size strips, and several stirrup positioning grooves are spaced apart on the size strips; The second positioning structure includes a plurality of finger cylinders with front-end grippers, the finger cylinders corresponding to a plurality of horizontal ribs of the New Jersey guardrail steel cage; The steel cage fixing bracket includes several fixed plates and several movable plates. The movable plates are slidably mounted on the fixed plates. A movable plate driving mechanism is provided between the fixed plates and the movable plates. The movable plate driving mechanism is used to drive the opening and closing movement of the movable plates. The fixed plates and the movable plates are respectively provided with the contour notch of the New Jersey fence steel cage. The opening of the contour notch faces upward and the opening end of the contour notch is relatively wide. The movable plate driving mechanism includes a movable plate opening and closing driving cylinder and a movable plate slide rail. The movable plate opening and closing driving cylinder is mounted and fixed on the fixed plate and is used to drive the movable plate to slide back and forth along the movable plate slide rail. The lower part of the steel cage fixing bracket is provided with several longitudinal positioning plates, and several longitudinal grooves are formed between the longitudinal positioning plates. The fixing plate is installed in the longitudinal grooves. The upper two ends of the fixing plate are provided with transverse grooves, and transverse positioning plates are installed in the transverse grooves. The fixing plate is provided with a strip mounting groove, and the size strip is installed in the strip mounting groove by a strip adjustment mechanism; The strip adjustment mechanism includes a top screw rod and a top screw seat. The top screw seat is fixed on the fixed plate, and the top screw rod is installed on the top screw seat and one end is connected to the strip of the specified size. Ventilation pipes are provided on both sides of the steel cage fixing bracket, and the finger cylinder and the movable plate opening and closing drive cylinder are connected to the ventilation pipes.

2. A double-line New Jersey fence automatic welding process, implemented using the double-line New Jersey fence automatic welding line as described in claim 1, characterized in that, Includes the following steps: S1, to process the steel bars into stirrups and cross bars for the New Jersey fence steel cage; S2, the stirrups and transverse bars are manually placed at the corresponding positions in the positioning area of ​​the steel cage fixing bracket, the stirrups are positioned by the first positioning structure, and the transverse bars are positioned by the second positioning structure; S3, start the equipment, and the relevant fastening components will tighten the stirrups and cross bars; S4, Welding begins. The welding robot moves along the walking track from both sides of the steel cage fixing bracket and automatically welds each welding point of the stirrups and cross bars according to the control program until the welding of the entire New Jersey fence steel cage is completed. S5. After welding is completed, the relevant fastening components loosen their fastening of the stirrups and crossbars, and the welded New Jersey fence steel cage is removed as a whole.

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