Automatic welding method for total assembly of steel-UHPC (Ultra High Performance Concrete) combined bridge deck slab combined beam sections

Abstract

The invention discloses a steel-UHPC (Ultra High Performance Concrete) combined bridge deck slab composite beam segment total assembly automatic welding method, which relates to the technical field of bridge construction in fixed buildings, and comprises the following steps: S1, positioning a central flat bottom plate unit, fixing the central flat bottom plate unit with a jig frame, then positioning and assembling flat bottom plate units on two sides, and finally assembling an inclined bottom plate unit to form a bottom plate unit; s2, assembling a middle partition plate unit on the bottom plate unit, temporarily supporting the middle partition plate unit, then positioning a middle web plate unit, and finally welding the middle web plate unit, the middle partition plate unit and the bottom plate unit; s3, the side partition plate units and the side web plate units are sequentially spliced on the inclined bottom plate units, and then the side partition plate units, the side web plate units and the inclined bottom plate units are welded; s4, the side top plate units and the anchor web plate units are positioned and welded; and S5, bridge deck prefabricated slabs are assembled, and then positioning, welding and fixing are conducted. The invention further discloses the technical problems that the labor intensity is high and the quality stability is poor during production of the steel-UHPC composite bridge deck slab composite beam.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge construction in fixed buildings, and particularly to an automated welding method for the overall assembly of steel-UHPC composite bridge deck composite beam segments. Background Art

[0002] As a new type of bridge structure, the composite beam of steel-UHPC composite bridge deck forms an integral stress system through shear connectors between the steel beam and the UHPC bridge deck, integrating the material advantages of steel and ultra-high performance concrete (UHPC). The excellent mechanical properties of ultra-high performance concrete allow the thickness of the bridge deck to be significantly reduced (usually 40-60 mm), significantly reducing the self-weight of the structure. Combined with the high-strength characteristics of the steel beam, the overall self-weight of the structure is reduced by 20% - 30% compared with traditional composite beams, which can effectively improve the bridge spanning ability, reduce the load demand of the lower structure, and save project costs.

[0003] Currently, in the production of plate units of steel-UHPC composite bridge deck composite beams, robotic welding technology has been gradually adopted. For example, for the U-ribs and plate ribs of plate units, a gantry multi-nozzle welding special machine is used in cooperation with a hydraulic anti-deformation jig for automated welding, for diaphragm units, a programming teaching double-arm welding robot is used for automated welding, and for I-shaped members, a cantilever submerged arc welding special machine is used for automated welding, etc. However, when the overall assembly of steel-UHPC composite bridge deck composite beam segments is carried out, due to space limitations and structural complexity, traditional gantry welding robots cannot be applied, and it still mainly relies on manual gas shielded welding or semi-automatic submerged arc welding, with high manual labor intensity and poor quality stability. Therefore, improving the automation rate of the overall assembly welding of steel-UHPC composite bridge deck composite beam segments, controlling the welding quality stability, and ensuring the post-welding accuracy of composite beam segments are key technologies in green bridge construction and have become major problems that urgently need to be solved. Summary of the Invention

[0004] The purpose of the present invention is to provide an automated welding method for the overall assembly of steel-UHPC composite bridge deck composite beam segments, which solves the technical problems of high labor intensity and poor quality stability in the production of steel-UHPC composite bridge deck composite beams in the prior art.

[0005] The embodiments of the present application disclose an automated welding method for the overall assembly of steel-UHPC composite bridge deck composite beam segments, including the following steps: S1: Locate the central flat bottom plate unit, fix it to the jig, then locate and assemble the flat bottom plate units on both sides, and finally assemble the inclined bottom plate unit to form the bottom plate unit; S2: Assemble the intermediate diaphragm unit on the bottom plate unit and temporarily support it, then locate the middle web unit, and finally weld the middle web unit, the middle diaphragm unit, and the bottom plate unit; S3: Assemble the side partition units and side web units on the inclined bottom plate unit in sequence, and then perform welding between the side partition units, side web units and the inclined bottom plate unit; S4: Position and weld the side top plate unit and the anchor web unit; S5: Assemble the precast bridge deck slab, and then perform positioning welding for fixation.

[0006] This application improves the welding sequence and welding method, enhances the total assembly welding automation rate of the steel-UHPC composite bridge deck combined beam segment, controls the stability of its welding quality, and ensures the post-welding accuracy of the combined beam segment.

[0007] Based on the above technical solutions, the embodiments of this application can also be improved as follows: Further, the specific content of step S1 is as follows: S101: Based on the central ground line and the transverse baseline at the end of the jig, position the flat bottom plate unit at the central position. After positioning, use elastic clamping plates to weld and fix it to the jig; S102: Based on the longitudinal baseline and transverse baseline of the flat bottom plate unit at the central position, position and assemble the flat bottom plate units on both sides; S103: Based on the central web ground line and the transverse baseline of the flat bottom plate unit, position the inclined bottom plate unit on the center side of the bridge; S104: Place heavy objects on the flat bottom plate unit for auxiliary pressing so that the gap between the bottom side of the flat bottom plate unit and the top side of the jig does not exceed 1 mm; S105: Use a trackless crawling welding robot and a gas metal arc welding equipment for combined welding, and perform longitudinal butt welding between the bottom plate units symmetrically from the center in the same direction. The beneficial effect of this step is to ensure the welding quality by designing the welding sequence.

[0008] Further, the specific content of step S2 is as follows: S201: Based on the partition position line and the central ground line on the bottom plate unit, assemble the partition unit; S202: After assembly, use adjustable temporary diagonal braces to support the partition unit. There are at least two support points on each side of the partition unit; S203: Based on the transverse baseline of the flat bottom plate unit and the inner and outer skin lines of the central web, position the lower long side of the central web unit, and then use the central web ground line and the web center line on the outer surface of the upper flange of the central web as the basis to position the upper long side of the central web unit; S204: Use a vision - teaching collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the notch welds between the middle partition unit and the middle web unit, and the flat bottom plate unit in a centered manner. Finally, use a drag - teaching collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the transverse longitudinal fillet welds between the middle web unit and the flat bottom plate unit in the same direction. The beneficial effect of this step is that through various benchmarks, the welding accuracy can be better guaranteed.

[0009] Further, the specific content of step S3 is as follows: S301: Assemble the side partition unit at the partition position on the inclined bottom plate unit; S302: Locate the lower edge of the side web based on the transverse baseline and the inner and outer skin lines of the side web on the inclined bottom plate unit, and then use the side measuring tower and the center of the side web to locate the upper edge of the side web unit; S303: Use a vision - teaching collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the notch welds between the side partition unit and the side web unit, and the flat bottom plate unit in a centered manner; S304: Use a drag - teaching collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the flat longitudinal fillet welds between the bottom plate and the side web in the same direction. The beneficial effect of this step is that through various benchmark positioning and combined with the robot, the welding work can be better completed.

[0010] Further, the specific content of step S5 is as follows: S501: Assemble the bridge deck precast slab based on the center line of the middle web, the longitudinal and transverse baselines of the segment, and the longitudinal and transverse baselines of the bridge deck precast slab, and fix it by positioning welding; S502: Use a drag - teaching collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the vertical butt welds and transverse fillet welds between the embedded parts and the partition in sequence.

[0011] Further, when automatically welding the longitudinal butt welds between the bottom plate units, adjust the welding torch of the trackless crawling welding robot to the front - mounted type; When automatically welding the flat longitudinal fillet welds between the side top plate unit and the side web unit, adjust the welding torch of the trackless crawling welding robot to the side - mounted type.

[0012] Further, during welding, the shielding gas is 80% Ar by volume and 20% CO 2 , the welding current is 240 - 260 A, the arc voltage is 26 - 28 V, the welding speed is 280 - 300 mm / min, the dry elongation is 12 - 18 mm, the gas flow rate is 25 - 30 L / min, the weaving mode is zigzag, the weaving width is 3 - 4 mm, the weaving frequency is 50 - 55 times / min, and the left - right pause duration is 0.4 s each.

[0013] Further, during welding, use CO2 Gas shielded welding mode, welding current is 170 - 190A, arc voltage is 23 - 25V, welding speed is 140 - 160mm / min, dry extension is 12 - 18mm, gas flow rate is 15 - 20L / min, swing arc mode is triangular, swing width is 4 - 6mm, swing frequency is 45 - 50 times / min, and the left and right stops are both 0.6s.

[0014] Furthermore, CO 2 Gas shielded welding mode, welding current is 220 - 240A, arc voltage is 24 - 26V, welding speed is 260 - 280mm / min, dry extension is 12 - 18mm, gas flow rate is 15 - 20L / min, swing arc mode is sinusoidal, swing width is 3 - 5mm, swing frequency is 85 - 90 times / min, and the left and right stops are both 0.5s.

[0015] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages: 1. The automatic welding method for the overall assembly of the steel - UHPC composite bridge deck girder segment of the present invention adopts a specific welding sequence, combines visual teaching collaborative robots, drag - teaching collaborative robots and a group of trackless crawling welding robots, and is combined with a gas metal arc welding equipment, and cooperates with welding tooling such as a horizontal hydraulic slide rail and an electric - drive lifting device to achieve the automatic high - quality welding of the steel - UHPC composite bridge deck girder segment in overall assembly, solving the production problem that in the current overall assembly process, traditional gantry - type welding robots cannot be applied, and still mainly rely on manual gas shielded welding or semi - automatic submerged arc welding, with high manual labor intensity and poor quality stability.

[0016] 2. The automatic welding method disclosed in the present application not only significantly improves the welding construction efficiency of the steel - UHPC composite bridge deck girder segment in overall assembly, greatly shortens the manufacturing period, but also effectively guarantees the welding quality stability and the overall post - welding accuracy, strongly promotes the application of automatic welding technology in the manufacture of steel bridges, and accelerates the transformation of bridge construction technology towards green and low - carbon. Brief Description of the Drawings

[0017] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following will briefly introduce the drawings required for use in the description of the specific embodiments or the prior art. Obviously, the following - described drawings are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0018] Figure 1 It is a schematic structural diagram of the steel - UHPC composite bridge deck girder segment described in the specific embodiment of the present invention; Figure 2 Schematic diagram of the overall assembly welding process of the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 3 It is a schematic diagram of the welding sequence of the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention. In the figure, the digital serial numbers ①-⑮ represent the welding sequence, and the arrow direction is the welding direction; Figure 4 Schematic diagram of the automated welding of the longitudinal butt weld between the bottom plate units in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 5 Schematic diagram of the automated welding of the notch weld between the diaphragm plate and the bottom plate in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 6 Schematic diagram of the automated welding of the weld between the web plate and the bottom plate in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 7 Schematic diagram of the automated welding of the weld between the side top plate and the web plate in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 8 Schematic diagram of the automated welding of the weld between the UHPC embedded part and the diaphragm plate in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 9 Physical diagram of the calibration process of the visual teaching collaborative robot using a calibration board before welding in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 10 Physical diagram of the visual teaching collaborative robot spraying welding anti-spatter agent and dyeing the area to be welded before welding in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 11 Physical diagram of the visual teaching collaborative robot automatically generating a welding path in combination with an algorithm in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention; Figure 12 Physical diagram of the automated welding of the notch weld between the diaphragm plate and the bottom plate of the overall assembly of the steel-UHPC composite bridge deck combined beam segment in the automated welding method for the overall assembly of the steel-UHPC composite bridge deck combined beam segment described in the specific embodiment of the present invention.

[0019] 1 - Steel-UHPC composite bridge deck composite beam segment, 2 - Bottom plate unit, 3 - Middle partition unit, 4 - Middle web unit, 5 - Side partition unit, 6 - Side web unit, 7 - Side top plate unit, 8 - UHPC precast slab unit, 9 - UHPC embedded part, 10 - Trackless crawling welding robot, 11 - Visual teaching collaborative robot, 12 - Horizontal hydraulic slide rail, 13 - Drag teaching collaborative robot, 14 - Electric drive lifting device. Detailed implementation manners

[0020] The embodiments of the technical solutions of the present invention will be described in detail below with reference to the accompanying drawings. The following embodiments are only used to illustrate the technical solutions of the present invention more clearly, so they are only examples and cannot be used to limit the protection scope of the present invention. It should be noted that unless otherwise specified, the technical terms or scientific terms used in this application should have the ordinary meanings understood by those skilled in the art to which the present invention belongs.

[0021] In this application, unless otherwise clearly defined and limited, terms such as "installation", "connection", "fixation" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the communication inside two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0022] In order to better understand the above technical solutions, the above technical solutions will be described in detail below with reference to the accompanying drawings of the specification and specific implementation manners.

[0023] Embodiment 1: This application discloses an automatic welding method for the overall assembly of a steel-UHPC composite bridge deck composite beam segment. According to a specific welding sequence, a trackless crawling welding robot is used in combination with a gas metal arc welding equipment to complete the automatic welding operation of the longitudinal butt weld of the bottom plate unit. A visual teaching collaborative robot is used in combination with a gas metal arc welding equipment to complete the automatic welding operation of the notch weld between the partition unit and the bottom plate unit. A drag teaching collaborative robot is used in combination with a gas metal arc welding equipment to complete the automatic fillet weld between the web unit and the bottom plate unit. A trackless crawling welding robot is used in combination with a gas metal arc welding equipment to complete the automatic longitudinal fillet weld between the side top plate unit and the side web unit. A drag teaching collaborative robot is used in combination with a gas metal arc welding equipment to complete the automatic welding operation of the connection weld between the embedded part and the partition unit.

[0024] The specific model of the trackless crawling welding robot in this application is Boqing BOT-WTA20-322, or it can be other models of robots, as long as they can complete crawling welding; similarly, the specific model of the vision and drag teaching collaborative robot can be FANUC CRX-5IA, or it can be other models.

[0025] The specific steps in this application are as follows: S1: Locate the central flat bottom plate unit, fix it to the jig, then locate and assemble the flat bottom plate units on both sides, and finally assemble the inclined bottom plate unit to form the bottom plate unit; the specific content of step S1 is as follows: S101: Based on the central ground line and the transverse baseline at the end of the jig, it is necessary to ensure that the longitudinal and transverse baselines are strictly aligned. Locate the flat bottom plate unit at the central position (the flat bottom plate unit of this total assembly segment). After positioning, use elastic cleats to weld and fix it to the jig. This jig is the general assembly jig. S102: Based on the longitudinal and transverse baselines of the flat bottom plate unit at the located central position, use a tape measure to re-locate and assemble the flat bottom plate units on both sides. S103: Based on the middle web ground line and the transverse baseline of the flat bottom plate unit, locate the inclined bottom plate unit on the center side of the bridge. S104: Place heavy objects on the flat bottom plate unit for auxiliary pressing so that the gap between the bottom side of the flat bottom plate unit and the top side of the jig does not exceed 1 mm, which can ensure that the bottom side of the flat bottom plate unit is in close contact with the support surface of the jig. S105: Use a trackless crawling welding robot and a gas metal arc welding equipment for combined welding, and weld the longitudinal butt welds between the bottom plate units symmetrically from the middle in the same direction. S2: Assemble the middle diaphragm unit on the bottom plate unit and temporarily support it, then locate the middle web unit, and finally weld the middle web unit, the middle diaphragm unit and the bottom plate unit; among them, the specific content of step S2 is as follows: S201: Based on the diaphragm position line and the central ground line on the bottom plate unit, assemble the diaphragm unit. When assembling, pay attention to the diaphragm spacing, and evenly distribute the transverse bridge deviation on both sides. S202: After assembly, use adjustable temporary diagonal struts to support the diaphragm unit. There are at least two support points on each side of the diaphragm unit, and at the same time, weld single-sided K8 welds at both ends, and the length is not less than 50 mm. S203: Based on the transverse baseline of the flat bottom plate unit and the inner and outer skin lines of the middle web, locate the lower long side of the middle web unit, and then use the middle web ground line and the web center line on the outer surface of the upper flange of the middle web as the basis to locate the upper long side of the middle web unit. S204: Use a vision - taught collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the notch welds between the middle partition unit, the middle web unit, and the flat bottom plate unit in a centered manner. Finally, use a drag - taught collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the transverse longitudinal fillet welds between the middle web unit and the flat bottom plate unit in the same direction; S3: Assemble the side partition unit and the side web unit on the inclined bottom plate unit in sequence, and then perform welding between the side partition unit, the side web unit, and the inclined bottom plate unit. Specifically, the content of step S3 is as follows: S301: Assemble the side partition unit at the partition position on the inclined bottom plate unit. During assembly, pay attention to the perpendicularity and spacing of the side partition; S302: Locate the lower edge of the side web with reference to the transverse baseline on the inclined bottom plate unit and the inner and outer skin lines of the side web. Then use the side measuring tower and the center of the side web to locate the upper edge of the side web unit; S303: Use a vision - taught collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the notch welds between the side partition unit, the side web unit, and the bottom plate unit in a centered manner; S304: Use a drag - taught collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the flat longitudinal fillet welds between the bottom plate unit and the side web unit in the same direction. When automatically welding the notch welds between the partition unit and the bottom plate unit, after the welding path of the first notch is planned through vision teaching, the subsequent welding of other notches can skip the teaching process. At the same time, a transverse hydraulic slide rail is provided under the collaborative robot. After the welding of the previous notch is completed, it can automatically slide to the center line position of the next notch to achieve continuous automatic welding of multiple notches, significantly improving production efficiency. When automatically welding the notch welds between the partition unit and the web unit (including the middle web unit and the side web unit), and the bottom plate unit, to improve the visual recognition accuracy, a welding anti - spatter agent can be sprayed on the area to be welded for dyeing to avoid the reflection of the metallic luster after grinding and rust removal in the area to be welded, which affects the camera's capture of the real - time images of the workpiece and the weld; S4: Locate and weld the side top plate unit and the anchor web unit. Specifically, the content of step S4 is as follows: S401: Conduct preliminary positioning with reference to the transverse baseline of the anchor web, and then accurately locate the horizontal position of the side top plate unit with reference to the ground line of the anchor web and the longitudinal baseline of the side top plate unit. Use tack welding to fix the side top plate unit, the side partition unit, and the anchor web unit. During assembly, ensure that the gap between the side top plate unit and the partition unit is ≤1 mm, and ensure a root gap of 6 mm is opened between the side top plate unit and the anchor web unit; S402: Use a trackless crawling welding robot combined with a gas metal arc welding equipment to symmetrically weld the flat longitudinal fillet welds between the side top plate and the side web in the same direction; S5: Assemble the bridge deck precast slab, and then perform positioning welding and fixation. Specifically, the content of step S5 is as follows: S501: Assemble the precast bridge deck slabs with the center line of the middle web, the longitudinal and transverse baselines of the segment, and the longitudinal and transverse baselines of the precast bridge deck slabs as the benchmarks, and fix them by positioning welding. During assembly, use the guide plates and jacks on the diaphragm units to ensure the positioning and fine-tuning of the precast slabs. Adjust the elevation and then assemble and fix them by positioning welding.

[0026] S502: Use a drag-and-teach collaborative robot combined with a gas metal arc welding equipment to symmetrically weld the vertical butt welds and horizontal fillet welds between the UHPC embedded parts and the diaphragm units in sequence. When automatically welding the horizontal fillet weld between the UHPC embedded part and the diaphragm unit, an electric drive lifting device is provided under the collaborative robot. The drag-and-teach collaborative robot can match the welding height according to the position of the UHPC embedded part, avoiding high-altitude operations by personnel and significantly improving the construction safety factor.

[0027] To better complete the automatic welding of the overall assembly of beam segments, the present application designs the corresponding steps. Among them, when automatically welding the longitudinal butt welds between the bottom plate units, adjust the welding torch of the trackless crawling welding robot to a front-mounted type; in step S402, when automatically welding the horizontal longitudinal fillet weld between the side top plate unit and the side web unit, adjust the welding torch of the trackless crawling welding robot to a side-mounted type.

[0028] Among them, the trackless crawling welding robot (Boqing BOT-WTA20-322) does not require manual programming, uses laser scanning to identify the welding groove, and automatically plans the welding path. The robot control program calls the automatic pulsed argon-rich gas shielded welding mode. The gas shielded welding consumables are solid wire G69A4M21ZN2M4T (φ1.2mm), and the shielding gas is 80% Ar by volume and 20% CO 2 , the welding current is 240A or 260A or 250A (range 240A - 260A), the arc voltage is 26V or 27V or 28V (range 26 - 28V), the welding speed is 280mm / min or 290mm / min or 300mm / min (range 280 - 300mm / min), the dry elongation is 12mm or 15mm or 18mm (range 12 - 18mm), the gas flow rate is 25L / min or 28L / min or 30L / min (range 25 - 30L / min), the weaving mode is zigzag, the weaving width is 3mm or 4mm or 3.5mm (range 3 - 4mm), the weaving frequency is 50 times / min or 52 times / min or 55 times / min (range 50 - 55 times / min) 50 - 55 times / min, and the left and right stop durations are both 0.4s.

[0029] Among them, when the groove welds between the partition unit, the web unit and the bottom plate unit are automatically welded, the collaborative robot is equipped with a vision teaching device. The real-time images of the workpiece and the weld are captured by the camera, and the welding path is automatically generated by combining algorithms. Compared with conventional drag teaching and laser teaching, vision teaching is more suitable for multi-segment curve welds. For complex paths, there is no need for multiple adjustments, and the teaching time is shorter. That is, the FANUC CRX-5IA vision teaching collaborative robot is used for welding. The control program of this robot calls the automatic pulse CO 2 gas shielded welding mode. The welding material for gas shielded welding is flux-cored wire T624T1-1C1A-GXU (φ1.2mm). The welding current is 170A or 180A or 190A (range: 170A - 190A), the arc voltage is 23V or 24V or 25V (range: 23 - 25V), the welding speed is 140mm / min or 150mm / min or 160mm / min (range: 140 - 160mm / min), the dry elongation is 12mm or 15mm or 18mm (range: 12 - 18mm), the gas flow rate is 15L / min or 18L / min or 20L / min (range: 15 - 20L / min), the weaving mode is triangular, the weaving width is 4mm or 5mm or 6mm (range: 4 - 6mm), the weaving frequency is 45 times / min or 48 times / min or 50 times / min (range: 45 - 50 times / min), and the left and right stops are both 0.6s. Among them, when the fillet welds between the side web unit and the bottom plate unit, and between the embedded part and the partition are automatically welded, the collaborative robot uses the drag teaching function. The operator can directly drag the robot arm to program the welding path without using a traditional teaching device or writing code. It is more suitable for long straight welds and realizes fast and intuitive path planning. The robot control program calls the automatic pulse CO 2 gas shielded welding mode. The welding material for gas shielded welding is flux-cored wire T624T1-1C1A-GXU (φ1.2mm). The welding current is 220A or 230A or 240A (range: 220 - 240A), the arc voltage is 24V or 25V or 26V (range: 24 - 26V), the welding speed is 260mm / min or 270mm / min or 280mm / min (range: 260 - 280mm / min), the dry elongation is 12mm or 16mm or 18mm (range: 12 - 18mm), the gas flow rate is 15L / min or 18L / min or 20L / min (range: 15 - 20L / min), the weaving mode is sine-shaped, the weaving width is 3mm or 4mm or 5mm (range: 3 - 5mm), the weaving frequency is 85 times / min or 88 times / min or 90 times / min, and the left and right stops are both 0.5s.

[0030] Further description is made for this application: This application discloses an automated welding method for the overall assembly of a steel-UHPC composite bridge deck combined beam segment, where the steel-UHPC composite bridge deck combined beam segment includes a bottom plate unit, a middle partition unit, a middle web unit, a side partition unit, a side web unit, a side top plate unit, and a UHPC precast plate unit; the UHPC precast plate unit includes UHPC embedded parts and ultra-high performance concrete, and the UHPC embedded parts and ultra-high performance concrete are connected by cylinder head studs. When the steel-UHPC composite bridge deck combined beam segment is assembled integrally, all adjacent plate units are connected by welding. When processed by the welding method of this application, the labor intensity can be reduced, the construction efficiency can be improved, and the welding quality can also be ensured.

[0031] Among them, before welding, the trackless crawling welding robot needs to perform laser scanning and recognition on the welding groove. After scanning, it does not start arc and pre-walks 1.5 meters to determine the crawling state of the welding robot. If the walking deviation in the weld width direction exceeds 3 mm, the permanent magnet knob at the bottom of the robot needs to be adjusted. After the pre-walking is qualified, welding starts.

[0032] Among them, when the collaborative robot installs the visual teaching device for the first time, a calibration plate needs to be used for recognition and calibration. The calibration plate is provided with irregular patterns, and the real-time image on the calibration plate is captured by the camera, and the parameters of the visual teaching device are automatically adjusted in combination with the algorithm.

[0033] Among them, when the groove welds between the partition and the web and the bottom plate are automatically welded, when the fillet size of the groove weld does not exceed 6 mm, single-pass welding in the vertical position and flat fillet position can be carried out. When the fillet size of the groove weld is greater than 6 mm and does not exceed 10 mm, single-pass welding in the vertical position can be carried out, and two-pass welding is required in the flat fillet position.

[0034] Among them, the collaborative robots (including the drag teaching collaborative robot and the visual teaching collaborative robot) and the trackless crawling welding robot need to store the welding parameter package in the teaching device, and directly call the whole set during the construction process, which can ensure the accuracy of parameter selection and avoid repeated input.

[0035] Among them, the collaborative robot needs to be equipped with an arc tracking function. When the welding groove is irregularly opened, the swing arc path of the welding torch can be changed through parameter changes to achieve real-time deviation correction; the trackless crawling welding robot needs to be equipped with a laser deviation correction function. When the welding groove is irregularly opened, the groove contour can be recognized by laser, and the vehicle body walking path can be changed to achieve real-time deviation correction, avoiding the situation of welding deviation and ensuring the weld fusion quality.

[0036] Among them, the collaborative robot and the trackless crawling welding robot need to store the welding parameter package in the teach pendant and directly call the whole set during the construction process, which can ensure the accuracy of parameter selection and avoid repeated input.

[0037] Among them, the collaborative robot and the trackless crawling welding robot can perform data interaction with the digital production line system through the 5G network, automatically receive and feedback the total segment assembly manufacturing information, and realize the real-time progress monitoring of the total segment assembly of the steel-UHPC composite bridge deck combined beam.

[0038] The bottom plate unit, middle partition unit, middle web unit, side partition unit, side web unit, and side top plate unit in this application can be existing sub-assemblies, which will not be elaborated here.

[0039] In the description of this specification, a large number of specific details are illustrated. However, it can be understood that the embodiments of the present invention can be practiced without these specific details. In some instances, well-known methods, structures, and technologies are not shown in detail so as not to obscure the understanding of this specification. In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples", etc. means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered by the scope of the claims and the specification of the present invention.

Claims

1. The automated welding method for the overall assembly of steel-UHPC composite bridge deck combined beam segments is characterized in that: The following steps are involved: S1: Position the central flat floor unit and fix it to the tire frame, then position and assemble the flat floor units on both sides, and finally assemble the inclined floor unit to form a floor unit; S2: assembling the middle partition unit on the bottom plate unit and temporarily supporting it, then positioning the middle web unit, and finally welding the middle web unit, the middle partition unit and the bottom plate unit; S3: assembling the side diaphragm unit and the side web unit on the inclined bottom plate unit in sequence, and then welding the side diaphragm unit, the side web unit and the inclined bottom plate unit; S4: Positioning welding edge top plate element and anchor web plate element; S5: Assemble the precast bridge deck panels and then fix them by positioning welding.

2. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 1 is characterized in that: The specific content of step S1 is as follows: S101: Using the center ground sample line and the tire frame end transverse baseline as reference, locate the flat bottom plate unit at the center position, and after the positioning is completed, weld and fix it to the tire frame with an elastic plate; S102: Using the longitudinal baseline and the transverse baseline of the flat bottom plate unit at the center as reference, positioning and assembling the flat bottom plate units at both sides; S103: Using the mid-web ground sample line and the horizontal baseline of the flat bottom plate unit as reference, locate the inclined bottom plate unit on the center side of the bridge; S104: placing a heavy object on the flat bottom plate unit to assist in pressing, so that the gap between the bottom side of the flat bottom plate unit and the top side of the tire frame does not exceed 1 mm; S105: Use trackless crawling welding robot and consumable gas shielded welding equipment for joint welding, and weld the longitudinal butt welds between the base plate units symmetrically in the same direction.

3. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 2 is characterized in that: The specific content of step S2 is as follows: S201: Assembling the partition unit based on the partition position line and the center ground sample line on the bottom plate unit; S202: After the assembly is completed, the partition unit is supported by using an adjustable temporary diagonal brace, and each side of the partition unit has at least two points of support; S203: Using the horizontal baseline of the flat bottom plate unit and the inner and outer skin lines of the middle web plate as references, locate the lower long side of the middle web plate unit, and then use the middle web plate ground sample line and the web center line on the outer surface of the flange of the middle web plate as references to locate the upper long side of the middle web plate unit; S204: A visual teaching collaborative robot is used in combination with a consumable electrode gas shielded welding device to symmetrically weld the notch welds between the middle partition unit and the middle web unit and the flat bottom plate unit. Finally, a dragging teaching collaborative robot is used in combination with a consumable electrode gas shielded welding device to symmetrically weld the horizontal longitudinal fillet welds between the middle web unit and the flat bottom plate unit in the same direction.

4. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 3 is characterized in that: The specific content of step S3 is as follows: S301: Assembling the side partition plate unit at the partition plate position on the inclined bottom plate unit; S302: Locate the lower edge of the side web plate based on the horizontal baseline on the inclined bottom plate unit and the inner and outer skin lines of the side web plate, and locate the upper edge of the side web plate unit using the side measurement tower and the center of the side web plate; S303: Use visual teaching collaborative robots in conjunction with consumable gas shielded arc welding equipment to symmetrically weld the notch welds between the side partition plate unit and the side web plate unit, and the flat bottom plate unit; S304: A dragging teaching collaborative robot is used in conjunction with a consumable gas shielded welding device to weld the horizontal longitudinal fillet weld between the bottom plate and the side web symmetrically in the same direction.

5. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 4 is characterized in that: The specific content of step S4 is as follows: S401: Perform initial positioning based on the horizontal baseline of the anchor web, then accurately locate the lateral position of the edge top plate unit based on the anchor web ground sample line and the vertical baseline of the edge top plate unit, and fix the edge top plate unit, the edge diaphragm unit and the anchor web unit by positioning welding; S402: A trackless guided crawling welding robot is used in conjunction with a consumable gas shielded welding device to weld the horizontal longitudinal fillet weld between the side top plate and the side web plate symmetrically in the same direction.

6. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 5 is characterized in that: The specific content of step S5 is as follows: S501: Based on the centerline of the middle web, the longitudinal and transverse baselines of the segments, and the longitudinal and transverse baselines of the bridge deck precast panels, assemble the bridge deck precast panels and fix them by positioning welding; S502: Use a dragging teaching collaborative robot in conjunction with a consumable gas shielded welding device to symmetrically weld the vertical butt welds and the horizontal fillet welds between the embedded parts and the partitions.

7. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 6 is characterized in that: When the longitudinal butt welds between the base plate units are automatically welded, the welding gun of the trackless crawling welding robot is adjusted to a front-mounted type; When the horizontal longitudinal fillet weld between the side top plate and the side web plate is automatically welded, the welding gun of the trackless crawling welding robot is adjusted to a side-mounted type.

8. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 7 is characterized in that: During welding, the shielding gas is 80% Ar and 20% CO2 by volume, the welding current is 240-260A, the arc voltage is 26-28V, the welding speed is 280-300mm / min, the dry extension is 12-18mm, the gas flow rate is 25-30L / min, the arc swing mode is sawtooth, the swing width is 3-4mm, the swing frequency is 50-55 times / min, and the left and right stop time are both 0.4s.

9. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 7, characterized in that: CO2 gas shielded welding mode is adopted during welding, the welding current is 170-190A, the arc voltage is 23-25V, the welding speed is 140-160mm / min, the dry extension length is 12-18mm, the gas flow rate is 15-20L / min, the arc swing mode is triangular, the swing width is 4-6mm, the swing frequency is 45-50 times / min, and the left and right stop times are both 0.6s.

10. The automated welding method for overall assembly of steel-UHPC composite bridge deck combined beam segments according to claim 9, characterized in that: CO2 gas shielded welding mode is adopted during welding, the welding current is 220-240A, the arc voltage is 24-26V, the welding speed is 260-280mm / min, the dry extension length is 12-18mm, the gas flow rate is 15-20L / min, the arc swing mode is sinusoidal, the swing width is 3-5mm, the swing frequency is 85-90 times / min, and the left and right stop times are both 0.5s.

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