Multi-bracket node welding and high-altitude mounting system

Abstract

The invention relates to a multi-bracket joint welding and high-altitude mounting system. The multi-bracket joint welding and high-altitude mounting system comprises a modular welding system and a high-altitude mounting system. The modular welding system comprises a welding platform, a welding clamp, robot welding equipment and a pretreatment device. And the welding platform is used for pre-welding bracket nodes on the ground and accommodating a plurality of modules to be welded at the same time. The welding clamp fixes the connecting part, and it is ensured that welding seams are uniform and adjustable. The robot welding equipment automatically plans and executes welding, and the precision and speed are improved. The pretreatment device cleans and preheats the module before welding. The high-altitude installation system comprises a high-altitude operation platform, an automatic positioning system, an adjustable connector and a safety monitoring system. The working platform is provided with a hydraulic lifting and safety protection device, the bracket node module is lifted to the designated height, and safety is ensured. The adjustable connector realizes quick connection and fixation and supports fine adjustment. The safety monitoring system monitors the safety condition in the installation process in real time.

Description

Technical Field

[0001] The invention relates to the technical field of high-altitude tower installation, in particular to a multi-corbel node welding and high-altitude installation system. Background Art

[0002] The corbel node is a common connection method in steel structure buildings and is widely used in large buildings, bridges, towers and other structures. The main function of the corbel node is to transfer force and torque between building components to ensure the stability and safety of the structure. There are many problems in the practical application of traditional corbel node welding and installation technology, which are mainly reflected in the following aspects:

[0003] Welding quality is difficult to guarantee: Traditional welding technology relies on manual operation of welders, and welding quality is easily affected by factors such as welder technical level and working environment. Problems such as uneven welds and many welding defects are common, making it difficult to guarantee welding quality. In addition, welding of high-strength steel puts forward higher requirements on welding technology, and manual welding is difficult to meet high-quality welding needs.

[0004] High-altitude installation is difficult: The bracket nodes usually need to be installed at high altitudes. Traditional high-altitude installation methods require a lot of temporary support and complex installation procedures. There are great safety risks in high-altitude operations. Operators need to perform heavy physical labor in high-altitude environments, which is labor-intensive and has many safety hazards. Especially in windy environments, the difficulty and danger of installation operations are further increased.

[0005] Low installation efficiency: The traditional corbel node installation method is not only complicated, but also takes a long time to prepare and install. A large number of temporary supports and cumbersome installation procedures lead to a long overall construction period and low construction efficiency. In large-scale engineering projects, inefficient installation methods will affect the progress of the project and increase construction costs.

[0006] High construction cost: As welding quality is difficult to guarantee, traditional methods require multiple reworks, which increases construction costs. At the same time, a large amount of temporary support materials and complex installation equipment also make construction costs high. In the fiercely competitive construction market, how to reduce construction costs has become the focus of attention of various construction companies.

[0007] Large environmental impact: Traditional welding and installation methods will produce a lot of waste gas and waste slag, causing environmental pollution. At the same time, the working environment of manual welding is usually accompanied by high temperature and harmful gases, which also has an adverse effect on the health of welders. With the improvement of environmental protection requirements, traditional methods are difficult to meet environmental protection standards, and new solutions are urgently needed.

[0008] In response to the above problems, automated welding equipment and advanced installation technology have gradually been introduced into the field of modern construction. Automated welding equipment can achieve high-precision and high-efficiency welding operations, reducing the impact of human factors on welding quality. In addition, the application of modular installation technology allows the bracket nodes to be prefabricated on the ground and then installed at high altitude, which simplifies the installation process and improves construction efficiency. However, the existing automated welding equipment and modular installation technology still have shortcomings in practical applications, mainly reflected in the lack of automation and the lack of flexibility in modular design.

[0009] In order to further improve the welding quality and high-altitude installation efficiency of the corbel nodes, the present invention proposes a multi-corbel node welding and high-altitude installation system. The system adopts modular design and automated welding equipment, and overcomes many shortcomings of traditional methods through ground pre-welding and high-altitude rapid installation. Specifically, the technical solution of the present invention includes a modular welding system and a high-altitude installation system. The former is used for pre-welding of corbel nodes on the ground, and the latter is used for precise positioning and rapid installation during high-altitude operations. In this way, not only the welding quality and installation efficiency are improved, but also the construction cost and environmental impact are greatly reduced. Summary of the invention

[0010] The object of the present invention is to provide a multi-corbel node welding and high-altitude installation system to solve the problems raised in the above-mentioned background technology.

[0011] To achieve the above object, the present invention provides the following technical solution: a multi-corbel node welding and high-altitude installation system, including a modular welding system and a high-altitude installation system, wherein:

[0012] The modular welding system includes a modular welding platform, a welding fixture, a robot welding device and a pre-processing device. The modular welding platform is used for pre-welding of the corbel node on the ground and is designed to accommodate multiple corbel node modules for welding operations at the same time.

[0013] The welding fixture is used to fix the various connection parts of the corbel node module to ensure uniform welds, and has an adjustable structure to adapt to corbel nodes of different sizes;

[0014] The robot welding equipment includes a multi-axis robot and an automatic welding head, which can automatically complete the planning of the welding path and the welding operation, thereby improving the welding accuracy and speed; the pretreatment device is used to clean and preheat the bracket node module before welding to ensure the welding quality;

[0015] The aerial installation system includes an aerial work platform, an automatic positioning system, an adjustable connector and a safety monitoring system. The aerial work platform includes a hydraulic lifting system and a safety protection device for lifting the bracket node module to a specified installation height and ensuring the safety of the operator;

[0016] The automatic positioning system includes a laser locator and a sensor, which can detect the position and posture of the corbel node module in real time, and automatically adjust it through the control system to ensure installation accuracy;

[0017] The adjustable connector includes a bolt connector and an adjuster, which is used to achieve rapid connection and fixation between the corbel node modules, and can be fine-tuned according to actual needs to ensure the stability of the overall structure;

[0018] The safety monitoring system includes a camera and an alarm device, which is used to monitor the safety status during the installation process in real time and issue an alarm when an abnormality is found;

[0019] As a preferred technical solution of the present invention, the modular welding platform can accommodate at least four corbel node modules for simultaneous welding operations, and is equipped with a protective cover and a smoke exhaust system to protect the environment and the safety of operators during the welding process.

[0020] As a preferred technical solution of the present invention, the welding fixture has an adjustable clamping mechanism to adapt to corbel node modules of different sizes and shapes, and is equipped with a force sensor to ensure the uniformity and stability of the clamping force.

[0021] As a preferred technical solution of the present invention, the multi-axis robot of the robotic welding equipment can realize movement with at least six degrees of freedom to cover complex welding paths, and is equipped with an automatic welding parameter adjustment function to automatically adjust the welding current, voltage and speed according to different welding requirements.

[0022] As a preferred technical solution of the present invention, the hydraulic lifting system of the aerial work platform has an automatic stabilization device to ensure the stability of the platform during aerial operations, and is equipped with a remote control system for operators to control on the ground.

[0023] As a preferred technical solution of the present invention, the safety protection device includes a fence and a safety belt to prevent operators from accidentally falling when working at heights, and is equipped with a safety sensor to automatically activate safety protection measures when an accident occurs.

[0024] As a preferred technical solution of the present invention, the laser positioning device of the automatic positioning system can achieve millimeter-level positioning accuracy to ensure the installation accuracy of the corbel node module, and is equipped with an automatic calibration function to perform calibration before each use to ensure the continuity of the positioning accuracy.

[0025] As a preferred technical solution of the present invention, the bolted connector of the adjustable connector is made of high-strength material to ensure the firmness and durability of the connection, and is equipped with an anti-vibration design to reduce the impact of vibration on the connector during construction.

[0026] As a preferred technical solution of the present invention, the camera of the security monitoring system has a night vision function to ensure monitoring even under low light conditions, and is equipped with an image recognition function to automatically identify and record key steps in the installation process.

[0027] As a preferred technical solution of the present invention, the system also includes a quality inspection module for performing non-destructive inspection on the welded corbel node module to ensure that the welding quality meets the requirements. The quality inspection module includes an ultrasonic detector and an X-ray detector to comprehensively detect internal defects of the weld.

[0028] Beneficial effects:

[0029] The present invention proposes a multi-corbel node welding and high-altitude installation system. The system adopts modular design and automated welding equipment, and overcomes many shortcomings of traditional methods through ground pre-welding and high-altitude rapid installation. Specifically, the technical solution of the present invention includes a modular welding system and a high-altitude installation system. The former is used for pre-welding of corbel nodes on the ground, and the latter is used for precise positioning and rapid installation during high-altitude operations. In this way, not only the welding quality and installation efficiency are improved, but also the construction cost and environmental impact are greatly reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a system block diagram of the multi-corbel node welding and high-altitude installation system proposed by the present invention. DETAILED DESCRIPTION

[0031] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] The following is a specific implementation method for the above claims. This section will elaborate on how to implement each key step of the method:

[0033] Example 1: Multi-corbel node welding system: The multi-corbel node welding system includes a modular welding platform, a welding fixture, a robotic welding equipment and a pretreatment device. The modular welding platform is used for pre-welding of corbel nodes on the ground, and is designed to accommodate multiple corbel node modules for welding operations at the same time. The welding fixture is used to fix the various connection parts of the corbel node module to ensure uniform welds, and has an adjustable structure to accommodate corbel nodes of different sizes. The robotic welding equipment includes a multi-axis robot and an automatic welding head, which can automatically complete the planning of welding paths and welding operations, and improve welding accuracy and speed. The pretreatment device is used to clean and preheat the corbel node modules before welding to ensure welding quality.

[0034] Example 2: High-altitude installation system: The high-altitude installation system includes an aerial work platform, an automatic positioning system, an adjustable connector and a safety monitoring system. The aerial work platform includes a hydraulic lifting system and a safety protection device, which are used to lift the corbel node module to the specified installation height and ensure the safety of the operator. The automatic positioning system includes a laser locator and a sensor, which can detect the position and posture of the corbel node module in real time, and automatically adjust it through the control system to ensure installation accuracy. The adjustable connector includes bolt connectors and regulators, which are used to achieve rapid connection and fixation between corbel node modules, and can be fine-tuned according to actual needs to ensure the stability of the overall structure. The safety monitoring system includes a camera and an alarm device, which is used to monitor the safety status during the installation process in real time and issue an alarm when an abnormality is found.

[0035] Example 3: Construction process

[0036] On the ground, the welding of the corbel node module is completed using welding fixtures and robotic welding equipment.

[0037] Use transportation equipment to deliver the welded modules to the installation site.

[0038] Use the aerial work platform and automatic positioning system to lift the corbel node module to the installation position.

[0039] Use adjustable connectors to quickly connect and secure the modules to complete the overall installation.

[0040] Example 4: Design of welding fixture

[0041] The welding fixture has an adjustable clamping mechanism to accommodate different sizes and shapes of corbel node modules. The force sensor of the fixture can detect and adjust the clamping force to ensure the stability of the corbel node module and the uniformity of the weld during the welding process.

[0042] Example 5: Functions of Robotic Welding Equipment

[0043] The multi-axis robot of the robotic welding equipment can achieve at least six degrees of freedom to cover complex welding paths. The welding equipment is equipped with an automatic welding parameter adjustment function, which can automatically adjust the welding current, voltage and speed according to different welding requirements to improve welding quality and efficiency.

[0044] Example 6: Safety design of aerial work platform

[0045] The hydraulic lifting system of the aerial work platform has an automatic stabilization device to ensure the stability of the platform when working at high altitude. Safety protection devices include fences and safety belts to prevent operators from accidentally falling when working at high altitude. The platform is equipped with a remote control system, which allows operators to control it from the ground to improve safety.

[0046] Example 7: Precise positioning of the automatic positioning system: The laser positioning device of the automatic positioning system can achieve millimeter-level positioning accuracy to ensure the installation accuracy of the bracket node module. The system is equipped with an automatic calibration function, which is calibrated before each use to ensure the continuity of positioning accuracy.

[0047] Example 8: Anti-vibration design of adjustable connector

[0048] The bolted connection parts of the adjustable connector are made of high-strength materials to ensure the firmness and durability of the connection. The connector is designed with anti-vibration function to reduce the impact of vibration on the connection parts during construction and ensure the stability of the structure.

[0049] Example 9: Functions of the security monitoring system

[0050] The security monitoring system’s cameras have night vision capabilities, ensuring monitoring even in low-light conditions. The system is equipped with image recognition capabilities that can automatically identify and record key steps in the installation process, ensuring the traceability and safety of the construction process.

[0051] Embodiment 10: Quality detection module

[0052] The quality inspection module includes an ultrasonic detector and an X-ray detector, which are used to perform non-destructive testing on the welded bracket node module. The inspection module can detect defects inside the weld to ensure that the welding quality meets the requirements and improve the safety and reliability of the structure.

[0053] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "comprise", "include" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0054] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A multi-bracket node welding and high-altitude installation system, characterized in that: It includes modular welding system and high-altitude installation system, including: The modular welding system includes a modular welding platform, a welding fixture, a robot welding device and a pre-processing device. The modular welding platform is used for pre-welding of the corbel node on the ground and is designed to accommodate multiple corbel node modules for welding operations at the same time. The welding fixture is used to fix the various connection parts of the corbel node module to ensure uniform welds, and has an adjustable structure to adapt to corbel nodes of different sizes; The robot welding equipment includes a multi-axis robot and an automatic welding head, which can automatically complete the planning of the welding path and the welding operation, thereby improving the welding accuracy and speed; the pretreatment device is used to clean and preheat the bracket node module before welding to ensure the welding quality; The aerial installation system includes an aerial work platform, an automatic positioning system, an adjustable connector and a safety monitoring system. The aerial work platform includes a hydraulic lifting system and a safety protection device for lifting the bracket node module to a specified installation height and ensuring the safety of the operator; The automatic positioning system includes a laser locator and a sensor, which can detect the position and posture of the corbel node module in real time, and automatically adjust it through the control system to ensure installation accuracy; The adjustable connector includes a bolt connector and an adjuster, which is used to achieve rapid connection and fixation between the corbel node modules, and can be fine-tuned according to actual needs to ensure the stability of the overall structure; The safety monitoring system includes a camera and an alarm device, which are used to monitor the safety status during the installation process in real time and issue an alarm when an abnormality is found.

2. The multi-corbel node welding and high-altitude installation system according to claim 1 is characterized in that: The modular welding platform can accommodate at least four corbel node modules for simultaneous welding operations and is equipped with a protective cover and a smoke exhaust system to protect the environment and the safety of operators during the welding process.

3. The multi-corbel node welding and high-altitude installation system according to claim 2 is characterized in that: The welding fixture has an adjustable clamping mechanism to accommodate corbel node modules of different sizes and shapes, and is equipped with a force sensor to ensure uniformity and stability of the clamping force.

4. The multi-corbel node welding and high-altitude installation system according to claim 1 is characterized in that: The multi-axis robot of the robotic welding equipment is capable of achieving at least six degrees of freedom of movement to cover complex welding paths, and is equipped with a welding parameter automatic adjustment function to automatically adjust the welding current, voltage and speed according to different welding requirements.

5. The multi-corbel node welding and high-altitude installation system according to claim 1 is characterized in that: The hydraulic lifting system of the aerial work platform has an automatic stabilizing device to ensure the stability of the platform during aerial work, and is equipped with a remote control system so that the operator can control it on the ground.

6. The multi-corbel node welding and high-altitude installation system according to claim 5 is characterized in that: The safety protection device includes a fence and a safety belt to prevent the operator from accidentally falling when working at height, and is equipped with a safety sensor to automatically start safety protection measures when an accident occurs.

7. The multi-corbel node welding and high-altitude installation system according to claim 1 is characterized in that: The laser positioning device of the automatic positioning system can achieve millimeter-level positioning accuracy to ensure the installation accuracy of the corbel node module, and is equipped with an automatic calibration function to perform calibration before each use to ensure the continuity of positioning accuracy.

8. The multi-corbel node welding and high-altitude installation system according to claim 1 is characterized in that: The bolted connection pieces of the adjustable connector are made of high-strength material to ensure the firmness and durability of the connection, and are equipped with an anti-vibration design to reduce the impact of vibration on the connection pieces during construction.

9. The multi-corbel node welding and high-altitude installation system according to claim 1, characterized in that: The security monitoring system’s cameras have night vision capabilities to ensure monitoring even in low-light conditions, and are equipped with image recognition capabilities to automatically identify and record key steps during the installation process.

10. The multi-corbel node welding and high-altitude installation system according to claim 1, characterized in that: The system also includes a quality inspection module for performing nondestructive inspection on the welded corbel node module to ensure that the welding quality meets the requirements. The quality inspection module includes an ultrasonic detector and an X-ray detector to comprehensively inspect the internal defects of the weld.

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