Large galvanized corrugated plate welding device and method

Abstract

The invention discloses a large galvanized corrugated plate welding device and method, and belongs to the field of welding. The large galvanized corrugated plate welding device comprises a welding system and a positioning system which are arranged on a rail, the positioning system comprises an upper pressing block, a lower pressing block and a follow-up pressing wheel, the upper pressing block and the lower pressing block are matched with a corrugated plate in a follow-up mode, the follow-up pressing wheel is connected with the welding system in a follow-up mode, and the upper pressing block and the lower pressing block clamp and limit the corrugated plate and provide a welding work area on one side; the follow-up pressing wheel provides pressure for the upper pressing block and moves along the track along with the welding system. According to the device, the corrugated plate can be accurately limited in the welding process, thermal deformation and dislocation are prevented, splashing is reduced, the welding quality is improved, and the automation level of welding of the large corrugated plate is improved.

Description

Technical Field

[0001] The invention belongs to the field of welding, and in particular relates to a large-scale galvanized corrugated plate welding device and method. Background Art

[0002] The quay crane machine room is the storage place for the quay crane control equipment and is also the core of the quay crane control. In order to ensure the safety of the equipment, the quay crane machine room is usually made of galvanized corrugated sheet welded as the wall, and the good corrosion resistance and deformation resistance of the galvanized sheet are used to ensure the safety of the quay crane machine room set at high altitude. In the conventional process, the quay crane machine room is manufactured by manual lap welding using the carbon dioxide gas shielded welding process. Since the corrugated sheet used to manufacture the quay crane machine room is large in size and has a galvanized layer on the surface, it requires a lot of manpower for grinding. During the welding process, there is a lot of spatter, poor forming, long grinding and repairing time, and a low level of automation.

[0003] Patent CN113001080A discloses a panel assembly machine that can automatically weld corrugated plates. However, the device can only position the edges of the corrugated plates and perform spot welding at the connection positions through multiple welding guns. The positioning accuracy is poor and the spot welding connection strength is insufficient, which cannot meet the manufacturing requirements of the quay crane machine room.

[0004] Therefore, providing an automated large-scale galvanized corrugated plate welding device has positive significance for improving the welding efficiency and welding quality of the corrugated plate and reducing labor costs. Summary of the invention

[0005] The purpose of the present invention is to provide a large-scale galvanized corrugated plate welding device to improve the welding efficiency of the galvanized corrugated plate. The present invention also provides a large-scale galvanized corrugated plate welding method.

[0006] According to an embodiment of one aspect of the present invention, a large-scale galvanized corrugated sheet welding device is provided, the device comprising a support system, a positioning system and a welding system, wherein:

[0007] The support system comprises a track, and the support system is arranged above the positioning system;

[0008] The welding system is connected to the track and can move along the length direction of the track;

[0009] The positioning system includes a contoured pressure block and a follower pressure wheel. The contoured pressure block includes an upper pressure block and a lower pressure block. The upper pressure block and the lower pressure block are conformally matched with the corrugated plate and can provide clamping and limiting for the two corrugated plates to be welded. One side of the contoured pressure block provides a welding working area. The follower pressure wheel is in follow-up connection with the welding system and provides pressure to the upper pressure block. When the welding system moves, the follower pressure wheel moves along the upper pressure block.

[0010] The welding device uses a contoured pressure block to accurately limit the position of the corrugated plate to avoid dimensional deviations caused by factors such as thermal deformation during welding; at the same time, the follower pressure wheel follows the movement of the welding device to further press the welding position during welding to avoid warping deformation, effectively improving the welding quality of the corrugated plate and reducing spatter and rework. The welding device moves along the track to achieve automated welding and improve welding efficiency.

[0011] Furthermore, in some embodiments, the welding system includes a laser dezincification head and a laser welding head, the laser dezincification head is arranged at a front position along the moving direction of the laser system, and the laser welding head is arranged at a rear position along the moving direction relative to the laser dezincification head.

[0012] During the movement of the welding device, the laser dezincification head removes zinc from the galvanized corrugated sheet to be welded at the front side to reduce spatter during welding and improve the quality of the weld. Using a laser welding head for welding can effectively reduce heat input during welding, reduce thermal deformation, and improve welding quality.

[0013] Furthermore, in some embodiments, the device also includes a feeding mechanism, which includes a plurality of sponge suction cups, and the sponge suction cups can be adsorbed on the surface of the corrugated plate to allow the feeding mechanism to move the corrugated plate.

[0014] The feeding mechanism can realize automatic feeding, improve welding efficiency and save labor.

[0015] Furthermore, in some embodiments, the feeding mechanism further includes a conveying plate chain, and the conveying plate chain is disposed between the upper pressing block and the lower pressing block to move the corrugated plate from the feeding end to the welding working area.

[0016] Furthermore, in some embodiments, the positioning system further includes a side clamp, and the side clamp provides lateral compression to the corrugated plate to enable the corrugated plate to move horizontally.

[0017] The side clamp can align the corrugated plates to be welded on one side to improve the welding quality.

[0018] Furthermore, in some embodiments, the support system is configured as a gantry, and the track is arranged on the gantry.

[0019] Furthermore, in some embodiments, the gantry adopts a welded structure and is annealed.

[0020] The use of annealed heat-treated welding gantry enables the support system to have high load-bearing capacity and maintain dimensional accuracy without deformation during long-term welding operations.

[0021] Furthermore, in some embodiments, the number of the follower pressure wheels is two, which are respectively arranged in front and behind the welding system along the moving direction.

[0022] The two follow-up pressure wheels can further increase the pressure of the upper pressure block on the corrugated plate and improve the welding seam accuracy.

[0023] According to another embodiment of the present invention, a large galvanized corrugated sheet welding method is provided, the method using the large galvanized corrugated sheet welding device provided in any of the aforementioned embodiments, and comprising the following steps:

[0024] The two galvanized corrugated plates to be welded are transported to the large-scale galvanized corrugated plate welding device, so that the two galvanized corrugated plates to be welded are staggered by one or more wave crests, and are pressed by the contoured pressing block so that the joint position of the two galvanized corrugated plates to be welded is located in the welding work area, wherein the joint position is set on the inclined wall of the two galvanized corrugated plates to be welded;

[0025] The welding system is started and moved along the track to complete the lap welding of the two galvanized corrugated plates to be welded; during the welding process, the follower pressure wheel follows the welding system to press the contoured pressure block.

[0026] The arrangement of the weld on the inclined wall of the corrugated plate can reduce the shear stress borne by the weld structure and improve the welding strength; this method can realize the continuous automatic welding of large corrugated plates and effectively improve the production efficiency.

[0027] Furthermore, in some embodiments, the length of the corrugated plate is not longer than the length of the contoured pressing block, the weld overlap gap does not exceed 2 mm, and the welding speed is not less than 1500 mm / min. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a schematic diagram of the structure of a large galvanized corrugated plate welding device in one embodiment;

[0029] Figure 2 This is a schematic diagram of the structure of a feeding mechanism in one embodiment;

[0030] Figure 3 This is a schematic diagram of the structure of a positioning system in an embodiment;

[0031] Figure 4 This is a schematic diagram of the structure of a welding system in one embodiment;

[0032] Figure 5 Schematic diagram of the side clamp structure in one embodiment.

[0033] Meaning of the reference symbols:

[0034] 1-gantry; 11-track; 2-feeding mechanism; 21-feeding mechanism guide rail; 22-sponge suction cup; 23-loading area; 31-lower pressure block; 32-upper pressure block; 33-front follower pressure wheel; 34-rear follower pressure wheel; 40-welding work area; 41-zinc removal laser head; 42-welding laser head; 43-laser tracking device; 51-conveyor chain; 52-side clamp; 53-alignment side; 61-corrugated plate; 62-corrugated plate.

[0035] The purpose of the above drawings is to explain the present invention in detail so that those skilled in the art can understand the technical concept of the present invention, but it is not intended to limit the present invention. For the sake of simplicity, the above drawings only schematically illustrate the structures related to the technical features of the present invention, and do not strictly follow the actual proportions to draw the complete structure and all details. DETAILED DESCRIPTION

[0036] The present invention is further described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0037] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present invention. The phrase appearing in various locations in the specification does not necessarily refer to the same embodiment, nor is it limited to mutually exclusive independent or alternative embodiments. Those skilled in the art should be able to understand that the embodiments herein may be combined with other embodiments without causing structural conflicts.

[0038] In the description of this article, unless otherwise clearly specified and limited, the technical terms "installed", "connected", "connected" and the like should be understood in a broad sense, for example, it can be a movable connection, a fixed connection or an integral connection. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of this application can be understood according to specific circumstances.

[0039] In the description of this document, terms indicating orientation or positional relationships, such as "up", "down", "left", "right", "horizontal", "vertical", "height", "length", and "width", are intended to accurately describe the embodiments and simplify the description, but are not intended to limit the parts or structures involved to have a specific orientation, be installed or operate in a specific orientation, and should not be construed as a limitation on the embodiments in this document.

[0040] In the description of this article, the terms "first", "second" and the like are only used to distinguish different objects, and cannot be understood as indicating relative importance or limiting the quantity, specific order or primary and secondary relationship of the described technical features. In the description of this article, the meaning of "plurality" is at least two.

[0041] During the manufacturing process of the quay crane, the quay crane machine room is the core of the entire quay crane control as the storage place of the control equipment. In order to ensure the safety of the machine room at high altitude, galvanized corrugated plates are usually used as walls, mainly relying on the characteristics of galvanized corrosion resistance, high tensile strength, and strong anti-deformation ability to ensure the strength of the quay crane machine room at high altitude. In the traditional manufacturing mode of the quay crane machine room, the lap welds of the corrugated plates are welded by carbon dioxide gas shielded welding. Due to the presence of the zinc layer, the welding spatter is large, the weld is poorly formed, the manual operation is difficult, and the subsequent grinding and repair time is long. The production cycle of the machine room is lengthened, which seriously affects the work efficiency and slows down the production progress of the entire quay crane. The existing corrugated plate welding process has problems such as large spatter, poor forming, and long grinding and repair time in the lap weld.

[0042] In order to solve the above problems, an embodiment of one aspect of the present invention provides a large-scale galvanized corrugated plate welding device, which can effectively improve the efficiency of automated production, reduce the input of manpower and material resources, reduce production costs, shorten the production cycle, greatly reduce the impact of personnel in the production process, and improve the automation level of large-scale corrugated plate welding.

[0043] The welding device structure is as follows Figure 1 As shown, it includes a gantry 1 as a support system and a feeding mechanism 2. The gantry 1 is made of a welded steel beam structure and is annealed to ensure the strength and dimensional stability of the overall structure. The gantry is equipped with a manual maintenance platform, and the overall linear track structure is used to ensure movement accuracy. Lubrication is self-lubricating or maintenance-free lubrication.

[0044] Among them, Figure 2 As shown, the feeding mechanism includes a feeding mechanism guide rail 21, and a sponge suction cup 22 controlled by a servo motor lifting device can reciprocate along the feeding mechanism guide rail 21, and suck up the corrugated plate in the loading area 23 and move it to the plate chain conveyor through the lifting movement. After the corrugated plate 61 to be welded is conveyed to the downstream of the plate chain conveyor, the sponge suction cup 22 sucks up the corrugated plate 62 and overlaps the corrugated plate 61 with a peak offset, so as to facilitate subsequent welding.

[0045] like Figure 3 and Figure 4As shown, a track 11 is provided at the bottom of the gantry 1, and the welding system is connected to the track 11 and can move along the length direction of the track 11. The extension direction of the track 11 is the same as the extension direction of the corrugations of the corrugated plates 61 and 62, so that the welding system can weld and connect the overlapping corrugated plates 61 and 62. The welding system includes a zinc removal laser head 41, a welding laser head 42, and a laser tracking device 43. A positioning system is also provided below the gantry 1, and the positioning system includes a lower pressing block 31, an upper pressing block 32, a front follower pressure wheel 33, and a rear follower pressure wheel 34. The top of the lower pressing block 31 has a concave structure, and the bottom of the upper pressing block 32 has a convex structure. The lower pressing block 31 and the upper pressing block 32 are in conformal cooperation with the corrugated plate to be welded, and can clamp the overlapping area of ​​the corrugated plate 61 and the corrugated plate 62 and form a limit. A welding work area 40 is formed on the downstream side of the upper pressing block 32 along the conveying direction of the plate chain conveyor. The boundary of the overlapping area of ​​the corrugated plate 61 and the corrugated plate 62 is limited within the welding work area 40, so that the welding system can perform welding operations. The front follower pressure wheel 33 and the rear follower pressure wheel 34 are connected to the welding system in a follow-up manner, and keep a fixed distance from the zinc removal laser head 41 and the welding laser head 42 in the horizontal direction, and move along the track 11 with the laser system. Driven by the driving device, the front follower pressure wheel 33 and the rear follower pressure wheel 34 can be vertically lifted and lowered to provide or remove pressure on the upper pressing block 32.

[0046] When welding, the welding system moves along the guide rail, and the front follower pressure wheel 33 and the rear follower pressure wheel 34 press down the upper pressure block 32 near the welding laser head 42 to fully press the corrugated plates 61 and 62 to be welded to prevent slippage and dislocation. The zinc removal laser head 41 is at the front position of the welding device, and performs zinc removal on the upper surface of the corrugated plate 62 to be welded to eliminate the galvanized layer in the welding area to reduce welding spatter; the welding laser head 42 is at the rear position of the welding device, and performs welding connection on the compressed corrugated plates 61 and 62. As the welding device moves, the front follower pressure wheel 33 and the rear follower pressure wheel 34 roll on the upper surface of the upper pressure block 32, so that the welded areas of the corrugated plates 61 and 62 are always kept compressed.

[0047] In a preferred embodiment, if Figure 5 As shown, a plurality of conveyor chains 51 convey the corrugated plates along the length direction, and a side clamp 52 is provided on one side of the conveyor chain 51. The side clamp 52 can push the corrugated plates to be welded sideways so that the corrugated plates are aligned at the alignment side 53 for welding.

[0048] The large-scale galvanized corrugated plate welding device provided in the above embodiment can automatically weld the lap welds of the corrugated plates with a length of 3.5m-12m, and can operate automatically and continuously without manual intervention.

[0049] In a preferred embodiment, using Figures 1 to 5 The process of corrugated plate welding by the large galvanized corrugated plate welding device shown is as follows:

[0050] The feeding mechanism 2 is used to feed the corrugated plates 61 and 62, which are sucked by the sponge suction cup 22 and transported to the welding station, so that the two corrugated plates overlap each other at a wave crest. After the plates are transported to the right place, the lower pressing block 31 rises and the upper pressing block 32 descends to clamp and position the corrugated plates at the overlapped part. The overlapping gap between the corrugated plates does not exceed 2mm, and the length of the corrugated plates to be welded is not longer than the length of the profiling pressing block, so that the overlapping areas of the corrugated plates are all in a compressed state. During welding, the front follower pressure wheel 33 and the rear follower pressure wheel 34 descend and press on the upper surface of the upper pressing block 32; the welding device moves along the track 11 as a whole, and the zinc removal laser head 41 performs laser zinc removal on the upper surface of the corrugated plate in the welding work area 40, and uses laser pulses to gasify the zinc coating on the upper surface of the corrugated plate 62 overlapped above in the welding area; the welding laser head 42 performs laser welding on the area after laser zinc removal, and the laser tracking device 43 tracks and detects the weld during the welding process to prevent welding deviation; the follower pressure wheel rolls on the upper surface of the upper pressing block 32 during the welding process to keep the upper pressing block 32 pressed tightly to ensure that the corrugated plate being welded is accurately limited; the plate is transported by the conveyor chain 51 to realize the movement on the production line, and is aligned on one side by the side clamp 52. In a preferred embodiment, the welding speed of this method can reach more than 1800mm / min, which is 140% higher than the welding speed of 750mm / min of manual welding in the comparative example.

[0051] The welding method provided in the above embodiment can ensure that the galvanized sheet welding weld is full and spatter-free. The laser welding has low heat input, small thermal deformation, large weld depth-to-width ratio, high welding speed and good weld strength. It can effectively reduce manual labor intensity, improve work efficiency while ensuring weld quality, optimize working hours and reduce quay crane manufacturing costs.

[0052] The purpose of the above embodiments is to further explain the present invention in detail in conjunction with the accompanying drawings so that those skilled in the art can understand the technical concept of the present invention. Within the scope of the present invention, the optimization or equivalent replacement of the part structure or method steps involved, and the combination of implementation methods in different embodiments without conflict of structure and principle, all fall within the protection scope of the present invention.

Claims

1. A large-scale galvanized corrugated sheet welding device, characterized in that: It includes support system, positioning system and welding system, among which: The support system comprises a track, and the support system is arranged above the positioning system; The welding system is connected to the track and can move along the length direction of the track; The positioning system includes a contoured pressure block and a follower pressure wheel. The contoured pressure block includes an upper pressure block and a lower pressure block. The upper pressure block and the lower pressure block are conformally matched with the corrugated plate and can provide clamping and limiting for the two corrugated plates to be welded. One side of the contoured pressure block provides a welding working area. The follower pressure wheel is in follow-up connection with the welding system and provides pressure to the upper pressure block. When the welding system moves, the follower pressure wheel moves along the upper pressure block.

2. The large-scale galvanized corrugated sheet welding device according to claim 1 is characterized in that: The welding system comprises a laser dezincification head and a laser welding head. The laser dezincification head is arranged at the front position of the laser system along the moving direction, and the laser welding head is arranged at the rear position along the moving direction relative to the laser dezincification head.

3. The large-scale galvanized corrugated sheet welding device according to claim 1 or 2, characterized in that: It also includes a feeding mechanism, which includes a plurality of sponge suction cups. The sponge suction cups can be adsorbed on the surface of the corrugated plate to allow the feeding mechanism to move the corrugated plate.

4. The large-scale galvanized corrugated sheet welding device according to claim 3 is characterized in that: The feeding mechanism also includes a conveying plate chain, which is arranged between the upper pressing block and the lower pressing block to move the corrugated plate from the feeding end to the welding working area.

5. The large-scale galvanized corrugated sheet welding device according to claim 1 or 2, characterized in that: The positioning system further comprises a side clamp, wherein the side clamp provides lateral compression to the corrugated plate to enable the corrugated plate to move horizontally.

6. The large-scale galvanized corrugated sheet welding device according to claim 1 or 2, characterized in that: The support system is configured as a gantry, and the track is arranged on the gantry.

7. The large-scale galvanized corrugated sheet welding device according to claim 6 is characterized in that: The gantry adopts a welded structure and is annealed.

8. The large-scale galvanized corrugated sheet welding device according to claim 1 or 2, characterized in that: The number of follower pressure wheels is two, which are respectively arranged in front and behind the welding system along the moving direction.

9. A large galvanized corrugated sheet welding method, characterized in that: A large-scale galvanized corrugated sheet welding device as claimed in any one of claims 1 to 8 is used, and comprises the following steps: The two galvanized corrugated plates to be welded are transported to the large-scale galvanized corrugated plate welding device, so that the two galvanized corrugated plates to be welded are staggered by one or more wave crests, and are pressed by the contoured pressing block so that the joint position of the two galvanized corrugated plates to be welded is located in the welding work area, wherein the joint position is set on the inclined wall of the two galvanized corrugated plates to be welded; The welding system is started and moved along the track to complete the lap welding of the two galvanized corrugated plates to be welded; during the welding process, the follower pressure wheel follows the welding system to press the contoured pressure block.

10. The large-scale galvanized corrugated sheet welding method according to claim 9, characterized in that: The length of the corrugated plate is not longer than the length of the contoured pressing block, the weld lap gap is not more than 2 mm, and the welding speed is not less than 1500 mm / min.

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