A large galvanized corrugated plate welding device and method

Abstract

The utility model relates to a large galvanized corrugated plate welding device and method, belongs to the field of welding. The large galvanized corrugated plate welding device includes a welding system and a positioning system arranged on a track, the positioning system includes an upper pressing block, a lower pressing block in conformal cooperation with the corrugated plate and a follow-up pressing wheel connected with the welding system, the upper pressing block and the lower pressing block provide clamping and limiting for the corrugated plate and provide a welding work area on one side, and the follow-up pressing wheel provides pressure for the upper pressing block and moves along the track following the welding system. The device can keep accurate limiting for the corrugated plate during the welding process, prevent thermal deformation and misplacement, reduce spatter, improve the welding quality and improve the automation level of large corrugated plate welding.

Description

Technical Field

[0001] This invention belongs to the field of welding, specifically relating to a welding device and method for large galvanized corrugated plates. Background Technology

[0002] The quay crane control room is the storage location for the quay crane control equipment and the core of the quay crane control system. To ensure equipment safety, the quay crane control room is typically constructed with galvanized corrugated steel sheets welded together for the walls. The excellent corrosion resistance and deformation resistance of the galvanized steel sheets ensure the safety of the quay crane control room located at a high altitude. In conventional processes, the quay crane control room is manufactured using carbon dioxide gas shielded welding through manual lap welding. Because the corrugated steel sheets used to manufacture the quay crane control room are large and have a galvanized layer on the surface, a large amount of manpower is required for grinding. The welding process results in significant spatter, poor forming quality, long grinding and repair times, and low automation levels.

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

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

[0005] The purpose of this invention is to provide a welding device for large galvanized corrugated sheets, thereby improving the welding efficiency of galvanized corrugated sheets. This invention also provides a welding method for large galvanized corrugated sheets.

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

[0007] The support system includes a track and is positioned above the positioning system.

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

[0009] The positioning system includes a contouring pressure block and a follower pressure roller. The contouring pressure block includes an upper pressure block and a lower pressure block. The upper pressure block and the lower pressure block conform to the corrugated plate and can provide clamping and limiting for the two corrugated plates to be welded. One side of the contouring pressure block provides a welding working area. The follower pressure roller is connected to the welding system and provides pressure to the upper pressure block. When the welding system moves, the follower pressure roller moves along the upper pressure block.

[0010] This welding device uses contour-following pressure blocks to precisely limit the position of the corrugated plate, avoiding dimensional deviations caused by thermal deformation during welding. Simultaneously, a follow-up pressure roller moves with the welding device, further pressing the welding position during welding to prevent warping and deformation, effectively improving the welding quality of the corrugated plate and reducing spatter and rework. The welding device moves along a track, enabling automated welding and improving welding efficiency.

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

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

[0013] Furthermore, in some embodiments, the device further includes a feeding mechanism comprising a plurality of sponge suction cups capable of adhering to the surface of the corrugated plate to allow the feeding mechanism to move the corrugated plate.

[0014] The feeding mechanism enables automatic material feeding, improving welding efficiency and saving labor.

[0015] Furthermore, in some embodiments, the feeding mechanism further includes a conveyor chain disposed between the upper pressure block and the lower pressure 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 that provides lateral pressure on the corrugated plate to move the corrugated plate horizontally.

[0017] Side clamps can align one side of the corrugated plates to be welded, improving welding quality.

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

[0019] Furthermore, in some embodiments, the gantry adopts a welded structure and undergoes annealing treatment.

[0020] The use of annealed heat-treated welded 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 follower pressure rollers are configured as two, respectively located in front of and behind the welding system along the direction of movement.

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

[0023] According to another aspect of the present invention, a method for welding large galvanized corrugated sheets is provided. This method employs the large galvanized corrugated sheet welding apparatus provided in any of the foregoing embodiments and includes the following steps:

[0024] Two galvanized corrugated sheets to be welded are transported to the large galvanized corrugated sheet welding device, so that the two galvanized corrugated sheets to be welded are staggered by one or more crests, and are pressed together by the conforming pressure block, so that the joint position of the two galvanized corrugated sheets 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 sheets to be welded.

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

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

[0027] Furthermore, in some embodiments, the length of the corrugated plate is not longer than the length of the conforming pressure block, the weld overlap gap does not exceed 2mm, and the welding speed is not less than 1500mm / min. Attached Figure Description

[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 feeding mechanism structure in one embodiment;

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

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

[0032] Figure 5 This is a schematic diagram of the side clamp structure in one embodiment.

[0033] Meaning of the reference numerals in the attached figures:

[0034] 1-Gantry; 11-Railway; 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 roller; 34-Rear follower pressure roller; 40-Welding work area; 41-Zinc removal laser head; 42-Welding laser head; 43-Laser tracking device; 51-Conveyor chain; 52-Side clamp; 53-Aligning side; 61-Corrugated plate; 62-Corrugated plate.

[0035] The purpose of the above-described drawings is to provide a detailed description of the present invention so that those skilled in the art can understand the technical concept of the invention, and is not intended to limit the invention. For the sake of brevity, the above-described drawings only schematically depict the structures related to the technical features of the present invention, and do not depict the complete structure and all details strictly according to actual scale. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to specific embodiments and accompanying drawings.

[0037] The term "embodiment" as used herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment herein. The phrase appearing in various places 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 will understand that the embodiments herein can be combined with other embodiments without causing structural conflicts.

[0038] In this description, unless otherwise explicitly specified and limited, the technical terms "installation," "connection," "joining," etc., should be interpreted broadly, for example, referring to movable connections, fixed connections, or integration. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application based on the specific circumstances.

[0039] In this description, terms such as "upper," "lower," "left," "right," "lateral," "longitudinal," "height," "length," and "width," which indicate orientation or positional relationships, are intended to accurately describe the embodiments and simplify the description, rather than limiting the parts or structures involved to have a specific orientation, or to be installed or operated in a specific orientation, and should not be construed as limiting the embodiments in this document.

[0040] In this description, terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating relative importance or limiting the number, specific order, or primary / secondary relationship of the described technical features. In this description, "multiple" means at least two.

[0041] In the manufacturing process of quay cranes, the quay crane machine room, as the storage location for control equipment, is the core of the entire quay crane control system. To ensure the safety of the machine room high in the air, galvanized corrugated steel sheets are typically used for the walls, relying primarily on their corrosion resistance, high tensile strength, and strong resistance to deformation to ensure the strength of the high-altitude quay crane machine room. In the traditional quay crane machine room manufacturing method, CO2 gas shielded welding is used to weld the corrugated steel sheet lap welds. The presence of the zinc layer leads to problems such as large welding spatter, poor weld formation, high difficulty in manual operation, and long subsequent grinding and repair time, resulting in a prolonged machine room manufacturing cycle, severely impacting work efficiency and slowing down the overall quay crane manufacturing progress. Existing corrugated steel sheet welding processes suffer from problems such as large welding spatter, poor weld formation, and long grinding and repair time for lap welds.

[0042] To address the aforementioned problems, one embodiment of the present invention provides a large-scale galvanized corrugated sheet welding device, which can effectively improve automated production efficiency, reduce the input of manpower and material resources, lower 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 sheet welding.

[0043] The structure of the welding device is as follows: Figure 1 As shown, the system includes a gantry 1 as a support system and a feeding mechanism 2. The gantry 1 is constructed of welded steel beams and undergoes annealing treatment to ensure the overall strength and dimensional stability of the structure. The gantry is equipped with a manual maintenance platform, and the overall structure uses a linear track framework to ensure movement accuracy. Lubrication is achieved through self-lubrication or maintenance-free lubrication.

[0044] Among them, such as Figure 2 As shown, the feeding mechanism includes a feeding mechanism guide rail 21. A sponge suction cup 22, controlled by a servo motor lifting device, can reciprocate along the feeding mechanism guide rail 21. Through the lifting motion, it picks up the corrugated plate in the loading area 23 and moves it onto the plate chain conveyor. After the corrugated plate 61 to be welded is conveyed to the downstream of the plate chain conveyor, the sponge suction cup 22 picks up the corrugated plate 62 and overlaps it with the corrugated plate 61 by one crest to facilitate subsequent welding.

[0045] like Figure 3 and Figure 4As shown, a track 11 is provided at the bottom of the gantry 1. The welding system is connected to the track 11 and can move along the length of the track 11. The extension direction of the track 11 is the same as the corrugation extension direction of the corrugated plates 61 and 62, enabling the welding system to weld the overlapping corrugated plates 61 and 62 together. 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, which includes a lower pressure block 31, an upper pressure block 32, a front follower pressure roller 33, and a rear follower pressure roller 34. The lower pressure block 31 has a concave structure at the top, and the upper pressure block 32 has a convex structure at the bottom. The lower pressure block 31 and the upper pressure block 32 conform to the corrugated plate to be welded, clamping and limiting the overlapping area of ​​the corrugated plate 61 and the corrugated plate 62. A welding working area 40 is formed on the downstream side of the upper pressure 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 restricted within the welding working area 40 to facilitate welding operations by the welding system. The front follower pressure roller 33 and the rear follower pressure roller 34 are connected to the welding system in a follower manner. They maintain 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 following the laser system. Driven by the drive device, the front follower pressure roller 33 and the rear follower pressure roller 34 can be vertically raised and lowered to apply or remove pressure to the upper pressure block 32.

[0046] During welding operations, the welding system moves along the guide rail. The front follower pressure roller 33 and the rear follower pressure roller 34 press down on the upper pressure block 32 near the welding laser head 42 to fully press the corrugated plates 61 and 62 to be welded, preventing slippage and misalignment. The zinc-removing laser head 41, at the front position of the welding device, removes zinc from the upper surface of the corrugated plates 62 to eliminate the zinc plating layer in the welding area, reducing welding spatter. At the rear position of the welding device, the welding laser head 42 welds the pressed corrugated plates 61 and 62 together. As the welding device moves, the front follower pressure roller 33 and the rear follower pressure roller 34 roll on the upper surface of the upper pressure block 32, ensuring that the areas of the corrugated plates 61 and 62 to be welded are always kept pressed firmly.

[0047] In a preferred embodiment, such as Figure 5 As shown, multiple conveyor chains 51 convey the corrugated plate along the length direction. A side clamp 52 is provided on one side of the conveyor chain 51. The side clamp 52 can push the corrugated plate to be welded from the side, so that the corrugated plate is aligned on the alignment side 53 for welding.

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

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

[0050] The feeding mechanism 2 is used for feeding, and the sponge suction cup 22 picks up the corrugated plates 61 and 62 and transports them to the welding station, so that the two corrugated plates overlap at one crest. After the plates are transported to the position, the lower pressure block 31 rises and the upper pressure block 32 descends to clamp and position the corrugated plates at the overlapping area. The overlap gap between the corrugated plates does not exceed 2mm, and the length of the corrugated plate to be welded is not longer than the length of the conforming pressure block, so that the overlapping area of ​​the corrugated plates is in a compressed state. During welding, the front follower pressure roller 33 and the rear follower pressure roller 34 descend and press against the upper surface of the upper pressure block 32; the welding device moves along the track 11, 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, using laser pulses to vaporize the zinc coating on the upper surface of the corrugated plate 62 overlapping above it in the welding area; the welding laser head 42 performs laser welding on the area that has undergone laser zinc removal, and during the welding process, the laser tracking device 43 tracks and detects the weld to prevent weld deviation; the follower pressure rollers roll on the upper surface of the upper pressure block 32 during the welding process to maintain pressure on the upper pressure block 32 and ensure that the corrugated plate being welded is accurately positioned; the plates are conveyed by the conveyor chain 51 to move on the production line and are aligned by the side clamp 52 on one side. In a preferred embodiment, the welding speed of this method can reach more than 1800 mm / min, which is 140% higher than the welding speed of 750 mm / min for manual welding in the comparative example.

[0051] The welding method provided in the above embodiments can ensure that the weld of galvanized sheet is full and spatter-free. 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 the intensity of manual labor, improve work efficiency, optimize working hours, and reduce the manufacturing cost of quay cranes while ensuring weld quality.

[0052] The purpose of the above embodiments is to provide a further detailed description of the present invention 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, optimization or equivalent substitution of the involved part structures or method steps, as well as combination of implementation methods in different embodiments without causing structural and principle conflicts, all fall within the protection scope of the present invention.

Claims

1. A welding method for large galvanized corrugated steel sheets, characterized in that, Welding is performed using a large-scale galvanized corrugated sheet welding device, which includes a support system, a positioning system, and a welding system, wherein: The support system includes a track and is positioned above the positioning system. The welding system is connected to the track and can move along the length of the track; The positioning system includes a contouring pressure block and a follower pressure roller. The contouring pressure block includes an upper pressure block and a lower pressure block. The upper pressure block and the lower pressure block conform to the corrugated plate and can provide clamping and limiting for the two corrugated plates to be welded. One side of the contouring pressure block provides a welding working area. The follower pressure roller is connected to the welding system and provides pressure to the upper pressure block. When the welding system moves, the follower pressure roller moves along the upper pressure block. The method includes the following steps: Two galvanized corrugated sheets to be welded are transported to the large galvanized corrugated sheet welding device, so that the two galvanized corrugated sheets to be welded are staggered by one or more crests, and are pressed together by the conforming pressure block, so that the joint position of the two galvanized corrugated sheets 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 sheets to be welded. The welding system is started, and the welding system moves along the track to complete the lap welding of the two galvanized corrugated plates to be welded; during the welding process, the follower pressure roller follows the welding system to press the conformal pressure block.

2. The welding method for large galvanized corrugated plates according to claim 1, characterized in that, The length of the corrugated plate is not longer than the length of the conforming pressure block, the weld overlap gap is not more than 2mm, and the welding speed is not less than 1500mm / min.

3. The welding method for large galvanized corrugated plates as described in claim 1, characterized in that... The welding system includes a laser zinc removal head and a laser welding head. The laser zinc removal head is located at the front of the welding system along the moving direction, and the laser welding head is located at the rear of the welding system relative to the laser zinc removal head along the moving direction.

4. The welding method for large galvanized corrugated plates according to claim 1 or 3, characterized in that, It also includes a feeding mechanism, which includes multiple sponge suction cups that can adhere to the surface of the corrugated plate to allow the feeding mechanism to move the corrugated plate.

5. The welding method for large galvanized corrugated plates according to claim 4, characterized in that, The feeding mechanism also includes a conveyor chain, which is disposed between the upper pressure block and the lower pressure block to move the corrugated plate from the feeding end to the welding work area.

6. The welding method for large galvanized corrugated plates according to claim 1 or 3, characterized in that, The support system is configured as a gantry, and the track is set on the gantry.

7. The welding method for large galvanized corrugated plates according to claim 6, characterized in that, The gantry is a welded structure and has undergone annealing treatment.

8. The welding method for large galvanized corrugated sheets according to claim 1 or 3, characterized in that, Two follower pressure rollers are configured, respectively located in front of and behind the welding system along the direction of movement.

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