A multi-angle adaptive bridge steel box girder welding robot system

Abstract

This invention discloses a multi-angle adaptive bridge steel box girder welding robot system, relating to the field of steel box girder welding technology. It addresses the problems of welding deformation and stress damage during the welding process of steel box girder structures. The system primarily utilizes a top plate pre-aligned onto a U-shaped rib, and an adaptive welding assembly first performs butt welding on adjacent U-shaped ribs. Subsequently, the longitudinal movement of the adaptive welding assembly completes the joint welding between the U-shaped rib and the top plate. During the joint / butt welding process, a deformation compensation assembly simultaneously compensates for the deformation of the U-shaped rib under pressure, preventing stress damage to the weld caused by deformation of the U-shaped rib under heavy load. This automated adaptive welding operation and deformation compensation action enable rapid welding of bridge steel box girders and improve welding efficiency.

Description

Technical Field

[0001] This invention relates to the field of steel box girder welding technology, specifically to a multi-angle adaptive bridge steel box girder welding robot system. Background Technology

[0002] As the core load-bearing structure of long-span bridges, the manufacturing quality of steel box girders directly affects the safety and lifespan of bridges. Steel box girders are mostly composed of top plates, bottom plates, webs, transverse diaphragms, longitudinal diaphragms, and stiffening ribs, which are connected by full welding. Stiffening ribs are auxiliary components in steel box girders, used to enhance the load-bearing capacity of the top plate, bottom plate, and web. U-shaped ribs, as longitudinal stiffening ribs, have good torsional resistance and stiffening effect. The welding between the U-shaped ribs and the top plate is particularly important.

[0003] In recent years, although automation technology has been introduced into the overall welding of steel box girders, traditional welding robot systems still have the following limitations: the spatial angles of irregular components such as U-shaped ribs and transverse diaphragms of steel box girders are complex. Common gantry welding equipment (refer to Chinese invention patent with patent publication number CN119820230A) achieves the joint welding between the U-shaped ribs and the top plate of the steel box girder by flipping the steel box girder. However, the flipping operation requires first inverting the top plate, welding the U-shaped ribs, and then resetting it. The operation is extremely cumbersome. At the same time, it lacks the ability to compensate for deformation in real time, resulting in welding deformation and stress damage.

[0004] Therefore, this application proposes a solution that involves welding U-shaped ribs normally on a top plate upright foundation, with deformation compensation performed in real time during the welding process to address the aforementioned technical defects. Summary of the Invention

[0005] The purpose of this invention is to provide a multi-angle adaptive bridge steel box girder welding robot system to solve the problems of welding deformation and stress damage in the welding process of steel box girder structures.

[0006] The objective of this invention can be achieved through the following technical solution: a multi-angle adaptive bridge steel box girder welding robot system, including a curved moving rail and a linear moving rail disposed on the outside of the top plate and U-shaped rib, wherein an adaptive welding component corresponding to the joint of the top plate and U-shaped rib is slidably installed on the curved moving rail, and the linear moving rail is disposed between two adjacent sets of top plate and U-shaped rib and is used for the longitudinal movement of the curved moving rail;

[0007] The inner wall of the U-shaped rib is provided with a deformation compensation component that abuts against the inner walls on both sides.

[0008] The bottom of the top plate and the U-shaped rib are provided with a preceding moving base and a following moving base at intervals. Each set of the top plate and the U-shaped rib moves closer, docks, and merges as a whole along the direction from the preceding moving base to the following moving base.

[0009] The welding assembly is further configured such that: the welding assembly includes a welding table slidably disposed on the outside of the curved moving rail, a slider is slidably mounted on the welding table, a lifting rod is mounted on the upper middle part of the slider, and a welding head is mounted on the output end of the lifting rod.

[0010] The welding table is further configured such that: movable seats are installed at both ends of the welding table, and traveling wheels that are slidably connected to the curved moving rail are installed on the movable seats.

[0011] The deformation compensation component is further configured such that: the deformation compensation component includes a lower platform rod symmetrically arranged at the bottom of the U-shaped rib, both ends of the lower platform rod are equipped with angular supports that contact the bottom corner of the U-shaped rib, and a vertical rod is installed at the middle of the upper end of the lower platform rod.

[0012] The configuration is further defined as follows: a cylinder is symmetrically installed on the upper end of the upright, a motor is installed inside the cylinder and a screw is connected to the output end of the motor, a threaded ring is threaded to the end of the screw, and an expansion frame is connected to the outside of the threaded ring to abut against the inner wall of the U-shaped rib.

[0013] A further configuration includes: a crossbar is installed between the upper ends of the pair of uprights, and a guide rod is installed at the lower end of the barrel, extending through the threaded ring, for guiding the axial movement of the expansion frame.

[0014] The structure is further configured such that: the top plate component includes a top plate one and a top plate two arranged in parallel; the U-shaped rib component includes a U-shaped rib one and a U-shaped rib two arranged in parallel; and the top plate one and U-shaped rib one, and the top plate two and U-shaped rib two, respectively constitute a steel box girder structure.

[0015] The configuration is further defined as follows: the curved moving rail is longitudinally slidably mounted on the linear moving rail, and a lifting rod is installed on the linear moving rail.

[0016] The configuration is further defined as follows: stepping wheels are evenly distributed on the preceding and following moving bases for horizontal movement of the top plate and the U-shaped rib.

[0017] The present invention has the following beneficial effects:

[0018] 1. This invention addresses the problems of welding deformation and stress damage in the welding process of steel box girder structures. It mainly utilizes the pre-positioning of the top plate on the U-shaped rib, and the use of an adaptive welding assembly to first perform butt welding on two adjacent U-shaped ribs. Then, the longitudinal movement of the adaptive welding assembly is used to complete the joint welding between the U-shaped rib and the top plate.

[0019] During the welding process of joints / butt joints, deformation compensation components are used to compensate for the deformation of the U-shaped ribs under pressure, preventing stress damage to the weld caused by deformation of the U-shaped ribs under heavy pressure. This automatic adaptation to welding operations and deformation compensation allows the welding process of bridge steel box girders to be carried out quickly and improves welding efficiency.

[0020] 2. In the overall welding process of the steel box girder, the steel box girder structure is first moved horizontally by the preceding moving base and the following moving base, so that the docking point of the adjacent set of steel box girder structures is in the middle position of the preceding moving base and the following moving base. Then, the welding components are adapted to weld the butt joint between the steel box girder structures after docking along the curved moving rail, and the welding components are adapted to weld the joint between the two sets of U-shaped ribs and the two sets of top plate components after docking along the straight moving rail.

[0021] After welding is completed, the preceding and following moving bases move the two sets of steel box girder structures out of the welded structure. The process of moving closer, docking, and merging as a whole is carried out continuously, which helps to form a continuous and uniform weld, improves welding quality and welding efficiency. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of the present invention;

[0024] Figure 2 This is a schematic diagram showing the movement state of the U-shaped rib and the top plate of the present invention;

[0025] Figure 3 This is a structural diagram of the deformation compensation component of the present invention.

[0026] Figure 4 This is a partial structural breakdown diagram of the deformation compensation component of the present invention;

[0027] Figure 5 This is a structural diagram of the installation of the welding assembly according to the present invention;

[0028] Figure 6 This is a structural diagram of the welding assembly adapted to the present invention;

[0029] Figure 7 This is a structural diagram of the movable base of the present invention;

[0030] Figure 8 This is a schematic diagram of the multi-angle welding state of the adaptive welding assembly of the present invention.

[0031] In the diagram: 1-1, preceding moving base; 1-2, subsequent moving base;

[0032] 2-1. Top Slab One; 2-2. Top Slab Two;

[0033] 3-1, U-shaped rib one; 3-2, U-shaped rib two;

[0034] 4. Curved moving rail; 5. Linear moving rail;

[0035] 6. Deformation compensation assembly; 61. Lower support rod; 62. Angle brace; 63. Vertical pole; 64. Machine barrel; 65. Extension frame; 66. Crossbar; 67. Screw; 68. Threaded ring;

[0036] 7. Adaptable welding components; 71. Welding table; 72. Movable seat; 73. Traveling wheels; 74. Slider; 75. Lifting rod; 76. Welding head;

[0037] 8. Lifting boom; 9. Stepping wheel. Detailed Implementation

[0038] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] Example 1: To address the problems of welding deformation and stress damage during the welding process of steel box girder structures, the following technical solution is proposed:

[0040] Reference Figure 1 - Figure 8 As shown, a multi-angle adaptive bridge steel box girder welding robot system in this embodiment includes a curved moving rail 4 and a linear moving rail 5 set on the outside of the top plate and U-shaped rib. An adaptive welding component 7 corresponding to the joint of the top plate and U-shaped rib is slidably installed on the curved moving rail 4. The linear moving rail 5 is set between two adjacent sets of top plate and U-shaped rib and is used for the longitudinal movement of the curved moving rail 4.

[0041] The welding assembly 7 includes a welding table 71 that is slidably disposed on the outside of the curved moving rail 4. A slider 74 is slidably mounted on the welding table 71. A lifting rod 75 is mounted on the upper middle part of the slider 74. A welding head 76 is mounted on the output end of the lifting rod 75. Movable seats 72 are mounted on both ends of the welding table 71. A traveling wheel 73 that is slidably connected to the curved moving rail 4 is mounted on the movable seat 72.

[0042] For the welding process of steel box girder structures, refer to... Figure 8 As shown, the welding process utilizes the longitudinal movement of the welding assembly along the joint between the top plate and the U-shaped rib in the steel box girder structure, combined with the movement along the joint adaptation curve between the two steel box girder structures. During the welding process, the welding head 76 can also be moved telescopically to complete the accurate welding of the joint position, reduce weld discontinuity, and make the welding process move from the middle to both sides to form symmetrical welding, reducing the probability of deformation and stress damage.

[0043] The inner wall of the U-shaped rib is provided with a deformation compensation component 6 that abuts against the inner walls on both sides. The deformation compensation component 6 includes a lower platform rod 61 symmetrically arranged at the bottom of the U-shaped rib. Both ends of the lower platform rod 61 are equipped with corner braces 62 that contact the bottom corner of the U-shaped rib. A vertical rod 63 is installed at the middle of the upper end of the lower platform rod 61.

[0044] A cylinder 64 is symmetrically installed on the upper end of the upright 63. A motor is installed inside the cylinder 64 and the output end is connected to a screw 67. A threaded ring 68 is threaded to the end of the screw 67. An expansion frame 65 that abuts against the inner wall of the U-shaped rib is connected to the outside of the threaded ring 68. A crossbar 66 is installed between the upper ends of a pair of uprights 63. A guide rod that passes through the threaded ring 68 is installed at the lower end of the cylinder 64 for guiding the axial movement of the expansion frame 65.

[0045] It is important to note that the expansion frame 65 is constructed by pre-welding a bolt to the inner wall of the U-shaped rib, and the expansion frame 65 is locked through the bolt with a nut. When the top plate is stacked on the U-shaped rib, the outward expansion force on the U-shaped rib can be relieved by the inward contraction of the expansion frame 65, thus achieving the purpose of deformation compensation. Of course, after the welding of the steel box girder is completed, the deformation compensation component 6 can be quickly removed by cutting the welded bolt.

[0046] For the deformation compensation process of the steel box girder structure, refer to section 3 and... Figure 4 As shown, after the butt welding of an adjacent pair of steel box girder structures is completed, the deformation compensation component 6 is installed on the inner wall of the U-shaped rib. The motor in the deformation compensation component 6 is connected to a controller, and a photoelectric sensor electrically connected to the controller is installed in the front view of the steel box girder structure during the welding process.

[0047] According to the design specifications, photoelectric sensors are used to measure the distance between the two top ends of each U-shaped rib in real time. The measured data is compared with the standard value of the design specifications to generate expansion or contraction signals, which are then sent to the motor in the deformation compensation component 6. The motor controls the screw 67 to rotate forward or backward according to the received signal, so that the symmetrically arranged expansion frame 65 drives the U-shaped rib to perform expansion or contraction actions in accordance with the design specifications. This avoids stress damage problems during the synchronous welding process, ensures the continuity of the weld and that the welded steel box girder meets the requirements.

[0048] The bottom of the top plate and the U-shaped rib are provided with a preceding moving base 1-1 and a following moving base 1-2 at intervals. Each set of top plate and U-shaped rib moves closer, docks and merges as a whole along the direction from the preceding moving base 1-1 to the following moving base 1-2.

[0049] The overall welding process of the steel box girder in this invention refers to Figure 2 and Figure 5 and Figure 7 As shown, the steel box girder structure is first moved horizontally by the preceding moving base 1-1 and the following moving base 1-2 in succession, so that the docking point of the adjacent set of steel box girder structures is in the middle position of the preceding moving base 1-1 and the following moving base 1-2.

[0050] Subsequently, the welding assembly 7 performs butt welding between the steel box girder structures after docking along the curved moving rail 4, and the welding assembly 7 performs joint welding between the two sets of U-shaped ribs and the two sets of top plate components after docking along the straight moving rail 5. After the welding is completed, the preceding moving base 1-1 and the following moving base 1-2 move the two sets of steel box girder structures after welding out.

[0051] The basic principle of this invention is as follows: it is carried out in the prefabrication plant of bridge steel box girders, and the welding operation between the top plate and the U-shaped rib is carried out simultaneously for two or more sets of steel box girder structures. Specifically, the top plate is pre-placed on the U-shaped rib, and the butt welding of two adjacent U-shaped ribs is carried out first by the adaptive welding assembly 7. Then, the longitudinal movement of the adaptive welding assembly 7 is used to complete the joint welding of the U-shaped rib and the top plate.

[0052] During the welding process of the joints / butt joints, deformation compensation components 6 are used to compensate for the deformation of the U-shaped ribs under pressure, preventing stress damage to the weld caused by deformation of the U-shaped ribs under heavy pressure. In other words, by combining the above-mentioned automated adaptive welding operation and deformation compensation action, the welding process of the bridge steel box girder can be carried out quickly and the welding processing efficiency can be improved.

[0053] Example 2: This example further optimizes the structure of the top plate and U-shaped ribs in Example 1, focusing on how they can be moved closer together, docked, and merged as a whole.

[0054] Reference Figure 1 and Figure 3 As shown, the top plate includes top plate 2-1 and top plate 2-2 arranged in parallel, and the U-shaped rib includes U-shaped rib 3-1 and U-shaped rib 3-2 arranged in parallel. Top plate 2-1 and U-shaped rib 3-1, and top plate 2-2 and U-shaped rib 3-2 respectively constitute a steel box girder structure.

[0055] The steel box girder structure can be connected by U-shaped rib 1 3-1 and U-shaped rib 2 3-2, and by the overall connection of U-shaped rib 1 3-1 and U-shaped rib 2 3-2, and top plate 1 2-1 and top plate 2 2-2, respectively, corresponding to two welding processes. In both welding processes, the curved corresponding movement of the welding component 7 is combined with the linear corresponding movement to continuously complete the welding, thereby continuously improving the welding quality of the weld.

[0056] The curved moving rail 4 is longitudinally slidably installed on the linear moving rail 5, and the linear moving rail 5 is equipped with a lifting rod 8. In combination with the above, the linear moving rail 5 is lifted above the middle of the welding station by the lifting rod 8. The curved moving rail 4 can move horizontally relative to the linear moving rail 5, so as to cooperate with the welding component 7 to complete two welding steps in the welding process, and can complete adaptive multi-angle welding processing according to the irregular structure of the steel box girder, thereby improving welding efficiency.

[0057] Stepping wheels 9 are evenly distributed on the preceding moving base 1-1 and the following moving base 1-2 for horizontal movement of the top plate and the U-shaped rib. Before, during, and after welding, the top plate and the U-shaped rib move horizontally via the stepping wheels 9 on the preceding moving base 1-1 and the following moving base 1-2, respectively, thereby realizing the process of the steel box girder structure approaching, docking, and merging as a whole along the direction from the preceding moving base 1-1 to the following moving base 1-2.

[0058] Structural advantages: This embodiment is based on embodiment one. It can continuously complete multi-angle welding of the steel box girder shape by using curve-corresponding movement combined with straight-line corresponding movement during the welding process, so that the overall weld is continuous and uniform, improving welding quality and welding efficiency.

[0059] Example 3: Refer to Figure 1 - Figure 8 As shown, this embodiment, combining Embodiment 1 and Embodiment 2, constitutes a multi-angle adaptive bridge steel box girder welding method, including the following steps:

[0060] Step 1: First, the steel box girder structure is continuously moved horizontally by the preceding moving base 1-1 and the following moving base 1-2, so that the docking point of the adjacent set of steel box girder structures is in the middle position of the preceding moving base 1-1 and the following moving base 1-2.

[0061] Step 2: Subsequently, the welding assembly 7 is adapted to weld the joints between the steel box girder structures after being joined along the curved moving rail 4, and the welding assembly 7 is adapted to weld the joints between the two sets of U-shaped ribs and the two sets of top plate components after being joined along the straight moving rail 5.

[0062] Step 3: During the welding synchronization process in Step 2, after completing the butt welding of adjacent pairs of steel box girder structures, the deformation compensation component 6 is installed on the inner wall of the U-shaped rib. A photoelectric sensor is used to measure the distance between the two top ends of each U-shaped rib in real time. The measured data is compared with the standard value of the design specification to generate an expansion or contraction signal and send it to the motor in the deformation compensation component 6. The motor controls the screw 67 to rotate forward or backward according to the received signal, so that the symmetrically set expansion frame 65 drives the U-shaped rib to perform expansion or contraction actions in accordance with the design specifications. This avoids stress damage problems during the synchronous welding process, ensures the weld is continuous and the welded steel box girder meets the requirements.

[0063] Step 4: After welding is completed, the stepping wheels 9 on the preceding moving base 1-1 and the following moving base 1-2 drive the two sets of steel box girder structures to move out after welding.

[0064] In summary: the main method is to pre-place the top plate on the U-shaped rib, and then use the adaptive welding assembly 7 to first perform the butt welding of two adjacent U-shaped ribs. Then, the longitudinal movement of the adaptive welding assembly 7 is used to complete the joint welding of the U-shaped rib and the top plate.

[0065] During the welding process of the joints / butt joints, deformation compensation components 6 are used to compensate for the deformation of the U-shaped ribs under pressure, preventing stress damage to the weld caused by deformation of the U-shaped ribs under heavy pressure. This automatic adaptation to the welding operation and the application of deformation compensation enables the welding process of the bridge steel box girder to be carried out quickly and improves the welding efficiency.

[0066] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A multi-angle adaptive bridge steel box girder welding robot system, comprising curved and linear moving tracks disposed on the outer sides of the top plate and U-shaped ribs, characterized in that, The curved moving rail is slidably mounted with an adaptive welding assembly corresponding to the joint of the top plate and the U-shaped rib. The linear moving rail is set between two adjacent sets of top plate and U-shaped rib and is used for the longitudinal movement of the curved moving rail. The inner wall of the U-shaped rib is provided with a deformation compensation component that abuts against the inner walls on both sides. The bottom of the top plate and the U-shaped rib are provided with a preceding moving base and a following moving base at intervals. Each set of the top plate and the U-shaped rib moves closer, docks, and merges as a whole along the direction from the preceding moving base to the following moving base. The welding assembly includes a welding table slidably disposed on the outside of a curved moving rail, a slider slidably mounted on the welding table, a lifting rod mounted on the upper middle part of the slider, a welding head mounted on the output end of the lifting rod, and movable seats mounted on both ends of the welding table, with traveling wheels slidably connected to the curved moving rail mounted on the movable seats. The deformation compensation component includes a lower platform rod symmetrically arranged at the bottom of the U-shaped rib. Both ends of the lower platform rod are equipped with angle braces that contact the bottom corners of the U-shaped rib. A vertical rod is installed at the middle of the upper end of the lower platform rod. A cylinder is symmetrically installed at the upper end of the vertical rod. A motor is installed inside the cylinder and a screw is connected to the output end. A threaded ring is threaded to the end of the screw. An expansion frame that abuts against the inner wall of the U-shaped rib is connected to the outside of the threaded ring. A crossbar is installed between the upper ends of the pair of uprights, and a guide rod is installed at the lower end of the barrel, extending through the threaded ring, for guiding the axial movement of the expansion frame; The expansion frame is constructed by pre-welding a bolt to the inner wall of the U-shaped rib, and locking the expansion frame through the bolt with a nut. When the top plate is stacked on the U-shaped rib, the outward expansion force on the U-shaped rib can be relieved by the inward contraction of the expansion frame, thus achieving the purpose of deformation compensation. After the welding of the steel box girder is completed, the deformation compensation component is quickly removed by cutting the welded bolt. The motor in the deformation compensation component is connected to a controller for communication, and photoelectric sensors that are electrically connected to the controller are installed in the front view of the steel box girder structure during the welding process. According to the design specifications, photoelectric sensors are used to measure the distance between the two top ends of each U-shaped rib in real time. The measured data is compared with the standard value of the design specifications to generate expansion or contraction signals and send them to the motor in the deformation compensation component. The motor controls the screw to rotate forward or backward according to the received signal.

2. The multi-angle adaptive bridge steel box girder welding robot system according to claim 1, characterized in that, The top plate component includes a top plate one and a top plate two arranged in parallel, and the U-shaped rib component includes a U-shaped rib one and a U-shaped rib two arranged in parallel. The top plate one and U-shaped rib one, and the top plate two and U-shaped rib two, respectively constitute a steel box girder structure.

3. The multi-angle adaptive bridge steel box girder welding robot system according to claim 1, characterized in that, The curved moving rail is longitudinally slidably installed on the linear moving rail, and a hoisting rod is installed on the linear moving rail.

4. The multi-angle adaptive bridge steel box girder welding robot system according to claim 1, characterized in that, The preceding and following moving bases are evenly distributed with stepping wheels for horizontal movement of the top plate and the U-shaped rib.

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