Anti-bending deformation protection measure implementation method in bar transportation process

Abstract

The invention relates to the technical field of industrial manufacturing, and discloses a method for implementing anti-bending deformation protection measures in the bar transportation process, and the method comprises the steps of S1, transportation tool pre-configuration, S2, bar loading and pre-supporting, S3, dynamic protection in the transportation process and S4, unloading buffering and precision reinspection. The number of supporting points (3 points for 6-8 m and 4 points for 8-12 m) of the hydraulic lifting type supporting bracket is automatically matched according to the length of the bar, the supporting distance error is smaller than or equal to 1, the arc-shaped rubber pad (the radian R is equal to the diameter of the bar plus 5 mm) is matched, the contact stress distribution uniformity is improved by 60%, the middle sagging amount is reduced to 0.2 mm / m from 2.8 mm / m according to a transportation experiment of a certain 6m aluminum alloy bar, real-time load closed-loop control is achieved, and the stability of the bar is improved. A strain type load sensor (the measuring range is 0-50 kN, and the precision is + / -0.5% FS) is linked with a hydraulic compensation system, and when the load fluctuation of a single supporting point exceeds the mean value by + / -15%, supporting force compensation is completed within 0.5 s.

Description

Technical Field

[0001] This invention relates to the field of industrial manufacturing technology, specifically to a method for implementing measures to prevent bending deformation during the transportation of bar stock. Background Technology

[0002] In modern industrial manufacturing, bar stock, as a key basic material, is widely used in high-precision fields such as aerospace, nuclear power equipment, and high-end machinery. For bars with an aspect ratio greater than 20, such as aluminum alloy 7075-T6 and 45# carbon structural steel, the straightness and surface roughness directly determine the yield of subsequent precision machining. For example, the maximum allowable bending deformation of a titanium alloy bar (diameter 80mm × length 12m) used for a certain aero-engine blade needs to be ≤0.03mm / m during transportation. However, the deformation caused by traditional transportation methods generally exceeds 0.5mm / m. This means that more than 60% of the bars need to be straightened before processing, which not only increases production costs but may also cause internal structural damage due to secondary processing.

[0003] The current technological development of bar transport fixtures lags behind the demands of high-end manufacturing. Early transport equipment largely adopted the extensive steel transport model, using fixed angle steel supports or concrete supports. This structure reveals significant defects when transporting bars with spans of 6-12m: when transporting 6m long 42CrMo alloy bars (theoretically weighing 280kg), the two-point support method resulted in a sagging of 4.2mm / m in the middle, exceeding the requirements for aerospace material processing by 14 times; and when transporting ultra-long bars over 10m, the traditional three-point support structure cannot dynamically adjust the spacing with the length, resulting in uneven load distribution at the support points. Actual measurement data from a steel plant showed that when the support point spacing was 3m and 3.5m, the internal stress difference of the bar could reach 37MPa, directly leading to a 22% increase in the cracking rate during the subsequent quenching process. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a method for implementing anti-bending deformation protection measures during bar transportation. It has advantages such as adaptive support structure optimization and solves the problem that bars need to be straightened before processing, which not only increases production costs but may also cause internal structural damage due to secondary processing.

[0005] (II) Technical Solution To achieve the above-mentioned adaptive support structure optimization objective, the present invention provides the following technical solution: a method for implementing anti-bending deformation protection measures during bar transportation, including S1 pre-configuration of transportation fixtures, S2 bar loading and pre-support, S3 dynamic protection during transportation, and S4 unloading buffer and accuracy re-inspection. The S1 pre-configuration of transportation fixtures includes S101 selection of adjustable support brackets and S102 installation of dynamic load sensors. Among them, S2 bar loading and pre-support includes S201 initial levelness calibration and S202 dynamic adjustment of pre-support force; Among them, the dynamic protection of the S3 transportation process includes the activation of the S301 and S302 anti-sway restraint devices for real-time load monitoring and compensation. Among them, S4 unloading buffer and precision re-check includes S401 unloading sequence control and S402 final check and data recording.

[0006] Preferably, the S101 adjustable support bracket is selected as follows: Select a "hydraulic lifting support bracket" according to the bar specifications. The bracket span is set according to the bar length: 3 points of support (2.5m-3m spacing) for 6-8m bars, and 4 points of support (3m-3.5m spacing) for 8-12m bars. The number of support points should be ≤1. The bracket support surface uses an arc-shaped rubber pad (arc R = rod diameter + 5mm), with a surface friction coefficient ≥0.6, to avoid sliding wear during transportation.

[0007] Preferably, the S102 dynamic load sensor is installed as follows: A strain gauge load sensor (range 0-50kN, accuracy ±0.5% FS) is embedded at the bottom of each support bracket. The sensor signal line is connected to the vehicle-mounted data acquisition system to monitor the force changes at each support point in real time.

[0008] Preferably, the initial levelness calibration in S201 is as follows: The level of the transport platform is adjusted using a laser level (accuracy ±0.1mm / m). The longitudinal tilt of the platform is ≤0.3mm / m, and the lateral tilt is ≤0.2mm / m. When hoisting the bars, a simultaneous hoisting method from both ends is adopted, and the hoisting speed is controlled at 0.2m / s-0.3m / s to ensure that the bars fall horizontally into the support bracket, and the deviation of the support point during the fall is ≤10mm.

[0009] Preferably, the pre-support force of S202 is dynamically adjusted: Start the bracket hydraulic system and automatically calculate the initial support force based on the weight of the bar: apply a support force of 0.8-1.2 kN / m for aluminum alloy bars and 1.5-2 kN / m for steel bars; After the support force is applied, the straightness of the bar is checked by a laser straightening instrument (measurement range 0-15m, accuracy ±0.05mm / m). If the sag in the middle is greater than 1mm, the height of the adjacent support points is finely adjusted (adjustment accuracy 0.1mm) until the straightness meets the standard.

[0010] Preferably, the S301 real-time load monitoring and compensation: The vehicle-mounted system collects load data at each support point at a frequency of 10Hz. When the load fluctuation at a single support point exceeds the mean ±15% (such as when passing over a pothole and causing an impact), the hydraulic system automatically compensates for the support force (compensation response time ≤0.5s) to maintain the balance of force at each point. Simultaneously using GPS positioning and an onboard tilt sensor (accuracy ±0.5°), it can predict the degree of road bumps in advance and automatically increase the support force by 10%-20% in scenarios involving curves and speed bumps.

[0011] Preferably, the S302 anti-sway restraint device is activated: When the vehicle speed exceeds 60km / h or the road slope is greater than 5°, the elastic restraint bands (tensile strength ≥500N) on both sides of the bracket are activated. The contact pressure between the restraint bands and the surface of the rod is controlled at 0.2MPa-0.3MPa, which limits radial sway (sway amplitude ≤5mm) and avoids excessive tightness and indentation.

[0012] Preferably, the unloading sequence control in S401 is as follows: Upon reaching the unloading point, the supporting force is gradually released in the order of "first the two ends, then the middle". The amount of unloading at each stage shall not exceed 30% of the initial force, and the unloading interval shall be ≥10 seconds to prevent deformation caused by instantaneous stress release. An air cushion buffer platform (buffer stroke 50mm-80mm, buffer force attenuation coefficient 0.6-0.8) is used to support the bar stock, and the platform surface levelness is ≤0.2mm / m.

[0013] Preferably, the S402 final inspection and data recording: The entire length of the bar is scanned using a 3D laser scanner (scanning accuracy ±0.03mm), and the bending deformation is recorded. If the deformation is greater than 0.5mm / m, the tooling calibration process is automatically triggered. Verticality calibration of support bracket: Use a right-angle ruler to check the verticality of the bracket column. If the deviation is >0.5°, correct it by adjusting the bolts (adjustment accuracy 0.1°). Load sensor calibration: Use standard weights (accuracy ±0.1%) to perform three-point calibration on the sensor. Replace the sensor if the error is >1%.

[0014] (III) Beneficial Effects Compared with the prior art, the present invention provides a method for implementing measures to prevent bending deformation during the transportation of bar stock, which has the following beneficial effects: 1. The implementation method of anti-bending deformation protection measures during the transportation of the bar stock is as follows: This solution achieves adaptive support structure optimization, and the hydraulic lifting support bracket automatically matches the number of support points according to the length of the bar stock (3 points for 6-8m, 4 points for 8-12m), with a support spacing error of ≤1 point. Combined with the arc-shaped rubber pad (arc R = bar stock diameter + 5mm), the uniformity of contact stress distribution is improved by 60%. A transportation experiment of a 6m aluminum alloy bar stock shows that the middle sag is reduced from 2.8mm / m to 0.2mm / m. Real-time load closed-loop control, with strain gauge load sensors (range 0-50kN, accuracy ±0.5% FS) linked with the hydraulic compensation system, when the load fluctuation at a single support point exceeds the average ±15%, the support force compensation is completed within 0.5s. When passing over speed bumps, the dynamic deformation of the bar is reduced by 75%. Actual test data from a logistics fleet shows that this function reduces the scrap rate of steel transportation from 8% to 1.2%.

[0015] 2. The implementation method of anti-bending deformation protection measures during the transportation of the bar stock includes unloading buffering and precision traceability. A graded unloading process of "two ends first, then the middle" (each unloading ≤30% of the initial force, interval ≥10s) combined with an air cushion buffer platform eliminates rebound deformation caused by instantaneous stress release. Three-dimensional laser scanning (accuracy ±0.03mm) automatically records deformation data. When deviations are exceeded, it triggers bracket verticality calibration (adjustment accuracy 0.1°) and sensor calibration, forming a closed-loop process. In a nuclear power project application, this increased the first-pass yield of the bar stock from 75% to 99.3%. The dynamic constraint anti-sway technology uses elastic constraint bands (tensile strength ≥ 500 N) that automatically activate at vehicle speeds > 60 km / h. The contact pressure is controlled at 0.2-0.3 MPa, keeping the radial sway amplitude within 5 mm and the surface friction coefficient ≤ 0.15. This avoids indentations caused by traditional rigid constraints. In a case involving the transportation of aerospace aluminum materials, the surface roughness Ra value was reduced from 1.6 μm to 0.8 μm, meeting the requirements of the anodizing process.

[0016] 3. The implementation method of anti-bending deformation protection measures during the transportation of the bar stock involves full-process digital monitoring. The vehicle-mounted data acquisition system records 12 parameters in real time, including support force, tilt angle, and GPS trajectory, forming a transportation quality traceability file. After application by a certain automobile factory, the cost of bar stock straightening was reduced by 65%. At the same time, by predicting road conditions in advance (such as automatically increasing the support force by 10%-20% on curves), the transportation efficiency was increased by 20% (the vehicle speed was increased from 40km / h to 60km / h). Detailed Implementation

[0017] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, those skilled in the art who have not made any innovative embodiments are all within the scope of protection of the present invention.

[0018] This invention provides a technical solution, specifically a method for implementing anti-bending deformation protection measures during bar transportation, including: S1 Pre-configuration of transportation fixtures: S101 Adjustable Support Bracket Selection: Select a "hydraulic lifting support bracket" according to the bar specifications. The bracket span is set according to the bar length: 3 points of support (2.5m-3m spacing) for 6-8m bars, and 4 points of support (3m-3.5m spacing) for 8-12m bars. The number of support points should be ≤1. The bracket support surface uses an arc-shaped rubber pad (arc R = rod diameter + 5mm), with a surface friction coefficient ≥0.6, to avoid sliding wear during transportation; S102 Dynamic Load Sensor Installation: A strain gauge load sensor (range 0-50kN, accuracy ±0.5% FS) is embedded at the bottom of each support bracket. The sensor signal line is connected to the vehicle data acquisition system to monitor the force changes at each support point in real time. S2 bar loading and pre-support: S201 Levelness Initial Calibration: The level of the transport platform is adjusted using a laser level (accuracy ±0.1mm / m). The longitudinal tilt of the platform is ≤0.3mm / m, and the lateral tilt is ≤0.2mm / m. When hoisting the bars, a simultaneous hoisting method from both ends is adopted, and the hoisting speed is controlled at 0.2m / s-0.3m / s to ensure that the bars fall horizontally into the support bracket, and the deviation of the support point during the fall is ≤10mm; S202 Pre-support force dynamic adjustment: Start the bracket hydraulic system and automatically calculate the initial support force based on the weight of the bar: apply a support force of 0.8-1.2 kN / m for aluminum alloy bars and 1.5-2 kN / m for steel bars; After the support force is applied, the straightness of the bar is checked by a laser straightening instrument (measurement range 0-15m, accuracy ±0.05mm / m). If the sag in the middle is >1mm, the height of the adjacent support points is finely adjusted (adjustment accuracy 0.1mm) until the straightness meets the standard. S3 Dynamic Protection During Transportation: S301 Real-time Load Monitoring and Compensation: The vehicle-mounted system collects load data at each support point at a frequency of 10Hz. When the load fluctuation at a single support point exceeds the mean ±15% (such as when passing over a pothole and causing an impact), the hydraulic system automatically compensates for the support force (compensation response time ≤0.5s) to maintain the balance of force at each point. Simultaneously using GPS positioning and an onboard tilt sensor (accuracy ±0.5°), it can predict the degree of road bumps in advance and automatically increase support by 10%-20% in scenarios involving curves and speed bumps; S302 anti-sway restraint device activated: When the vehicle speed exceeds 60km / h or the road slope is greater than 5°, activate the elastic restraint bands (tensile strength ≥500N) on both sides of the bracket. The contact pressure between the restraint bands and the surface of the rod is controlled at 0.2MPa-0.3MPa, which limits radial sway (sway amplitude ≤5mm) and avoids excessive tightness and indentation. S4 Unload Buffer and Accuracy Recheck: S401 Unloading Sequence Control: Upon reaching the unloading point, the supporting force is gradually released in the order of "first the two ends, then the middle". The amount of unloading at each stage shall not exceed 30% of the initial force, and the unloading interval shall be ≥10 seconds to prevent deformation caused by instantaneous stress release. An air cushion buffer platform (buffer stroke 50mm-80mm, buffer force attenuation coefficient 0.6-0.8) is used to support the bar stock, and the platform surface levelness is ≤0.2mm / m; S402 Final Inspection and Data Recording: The entire length of the bar is scanned using a 3D laser scanner (scanning accuracy ±0.03mm), and the bending deformation is recorded. If the deformation is greater than 0.5mm / m, the tooling calibration process is automatically triggered. Verticality calibration of support bracket: Use a right-angle ruler to check the verticality of the bracket column. If the deviation is >0.5°, correct it by adjusting the bolts (adjustment accuracy 0.1°). Load sensor calibration: Use standard weights (accuracy ±0.1%) to perform three-point calibration on the sensor. Replace the sensor if the error is >1%. This invention achieves a bar stock deformation of ≤0.3mm / m during transport through a dynamic protection system throughout the entire process, improving accuracy by 40% compared to traditional processes. Specific advantages are as follows: The adaptive support structure is optimized, and the hydraulic lifting support bracket automatically matches the number of support points according to the length of the bar (3 points for 6-8m, 4 points for 8-12m). The support spacing error is ≤1 point. With the help of the arc-shaped rubber pad (arc R = bar diameter + 5mm), the uniformity of contact stress distribution is improved by 60%. A transportation test of a 6m aluminum alloy bar showed that the sag in the middle decreased from 2.8mm / m to 0.2mm / m. Real-time load closed-loop control, with strain gauge load sensors (range 0-50kN, accuracy ±0.5% FS) linked to the hydraulic compensation system, when the load fluctuation at a single support point exceeds the average ±15%, the support force compensation is completed within 0.5s. When crossing speed bumps, the dynamic deformation of the bar is reduced by 75%. Actual test data from a logistics fleet shows that this function reduces the scrap rate of steel transportation from 8% to 1.2%. Unloading buffering and precision traceability: A staged unloading process, "unloading from both ends first, then the middle" (each stage unloading ≤30% of the initial force, interval ≥10s), combined with an air cushion buffer platform, eliminates rebound deformation caused by instantaneous stress release; 3D laser scanning (accuracy ±0.03mm) automatically records deformation data, triggering bracket verticality calibration (adjustment accuracy 0.1°) and sensor calibration when deviations occur, forming a closed-loop process. In a nuclear power project application, this increased the first-pass yield of steel bars from 75% to 99.3%. Dynamic constraint anti-sway technology: The elastic constraint band (tensile strength ≥500N) automatically activates when the vehicle speed is >60km / h, and the contact pressure is controlled at 0.2-0.3MPa, controlling the radial sway amplitude within 5mm. The surface friction coefficient is ≤0.15, avoiding indentations caused by traditional rigid constraints. In a case of transporting aviation aluminum materials, the surface roughness Ra value was reduced from 1.6μm to 0.8μm, meeting the requirements of the anodizing process. The entire process is digitally monitored. The vehicle-mounted data acquisition system records 12 parameters in real time, including support force, tilt angle, and GPS trajectory, forming a transportation quality traceability file. After applying this system, a car factory reduced the cost of bar straightening by 65%. At the same time, by predicting road conditions in advance (such as automatically increasing the support force by 10%-20% on curves), the transportation efficiency was improved by 20% (the vehicle speed was increased from 40km / h to 60km / h).

[0019] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for implementing anti-bending deformation protection measures during bar transportation, comprising S1 pre-configuration of transportation fixtures, S2 bar loading and pre-support, S3 dynamic protection during transportation, and S4 unloading buffering and accuracy re-inspection, characterized in that: The pre-configuration of the S1 transport tooling includes the selection of the S101 adjustable support bracket and the installation of the S102 dynamic load sensor. Among them, S2 bar loading and pre-support includes S201 initial levelness calibration and S202 dynamic adjustment of pre-support force; Among them, the dynamic protection of the S3 transportation process includes the activation of the S301 and S302 anti-sway restraint devices for real-time load monitoring and compensation. Among them, S4 unloading buffer and precision re-check includes S401 unloading sequence control and S402 final check and data recording.

2. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The S101 adjustable support bracket selection: Select "hydraulic lifting support bracket" according to the bar specifications. The bracket span is set according to the bar length: 3 points of support (2.5m-3m spacing) for 6-8m bars, and 4 points of support (3m-3.5m spacing) for 8-12m bars. The number of support points should be ≤1. The bracket support surface uses an arc-shaped rubber pad (arc R = rod diameter + 5mm), with a surface friction coefficient ≥0.6, to avoid sliding wear during transportation.

3. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The S102 dynamic load sensor is installed as follows: A strain gauge load sensor (range 0-50kN, accuracy ±0.5% FS) is embedded at the bottom of each support bracket. The sensor signal line is connected to the vehicle-mounted data acquisition system to monitor the force changes at each support point in real time.

4. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The initial levelness calibration of S201: The level of the transport platform is adjusted using a laser level (accuracy ±0.1mm / m). The longitudinal tilt of the platform is ≤0.3mm / m, and the lateral tilt is ≤0.2mm / m. When hoisting the bars, a simultaneous hoisting method from both ends is adopted, and the hoisting speed is controlled at 0.2m / s-0.3m / s to ensure that the bars fall horizontally into the support bracket, and the deviation of the support point during the fall is ≤10mm.

5. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The dynamic adjustment of the pre-support force in S202: Start the bracket hydraulic system and automatically calculate the initial support force based on the weight of the bar: apply a support force of 0.8-1.2 kN / m for aluminum alloy bars and 1.5-2 kN / m for steel bars; After the support force is applied, the straightness of the bar is checked by a laser straightening instrument (measurement range 0-15m, accuracy ±0.05mm / m). If the sag in the middle is greater than 1mm, the height of the adjacent support points is finely adjusted (adjustment accuracy 0.1mm) until the straightness meets the standard.

6. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The S301 real-time load monitoring and compensation: The vehicle-mounted system collects load data at each support point at a frequency of 10Hz. When the load fluctuation at a single support point exceeds the mean ±15% (such as when passing over a pothole and causing an impact), the hydraulic system automatically compensates for the support force (compensation response time ≤0.5s) to maintain the balance of force at each point. Simultaneously using GPS positioning and an onboard tilt sensor (accuracy ±0.5°), it can predict the degree of road bumps in advance and automatically increase the support force by 10%-20% in scenarios involving curves and speed bumps.

7. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The S302 anti-sway restraint device is activated: When the vehicle speed exceeds 60km / h or the road slope is greater than 5°, the elastic restraint bands (tensile strength ≥500N) on both sides of the bracket are activated. The contact pressure between the restraint bands and the surface of the rod is controlled at 0.2MPa-0.3MPa, which limits radial sway (sway amplitude ≤5mm) and avoids excessive tightness and indentation.

8. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The S401 unloading sequence control: Upon reaching the unloading point, the supporting force is gradually released in the order of "first the two ends, then the middle". The amount of unloading at each stage shall not exceed 30% of the initial force, and the unloading interval shall be ≥10 seconds to prevent deformation caused by instantaneous stress release. An air cushion buffer platform (buffer stroke 50mm-80mm, buffer force attenuation coefficient 0.6-0.8) is used to support the bar stock, and the platform surface levelness is ≤0.2mm / m.

9. The method for implementing the anti-bending deformation protection measure during the transportation of bars according to claim 1, characterized in that: The S402 final inspection and data recording: The entire length of the bar is scanned using a 3D laser scanner (scanning accuracy ±0.03mm), and the bending deformation is recorded. If the deformation is greater than 0.5mm / m, the tooling calibration process is automatically triggered. Support bracket verticality calibration: Use a right-angle ruler to check the bracket column. If the deviation is >0.5°, correct it by adjusting the bolts (adjustment accuracy 0.1°); Load sensor calibration: Use standard weights (accuracy ±0.1%) to perform three-point calibration on the sensor. If the error is >1%, replace the sensor.