Auxiliary positioning device for mounting and welding steel structure

Abstract

The invention discloses an auxiliary positioning device for mounting and welding a steel structure, relates to the technical field of steel structure welding, and aims to solve the problems of deviation and low accuracy during positioning of the device. According to the technical scheme, the device is characterized in that a laser ranging module is integrated on the outer side of a clamping mechanism and comprises at least four sets of laser emitters distributed in a spatial orthogonal mode, the four sets of laser emitters form a spatial positioning matrix, the deflection angle of a component is calculated through a triangulation method, and three-dimensional space coordinates of the component and a target installation point are collected in real time; and an industrial PLC and a welding deformation prediction algorithm module are arranged in the controller, and the controller is used for receiving the three-dimensional coordinate data of the laser ranging module. The controller generates the pre-compensation amount through the welding deformation prediction algorithm module, drives the hydraulic clamping jaw to adjust the pose through PID control according to laser ranging data, monitors the clamping pressure, the positioning precision and other parameters in real time, triggers an alarm and protection mechanism when the parameters are out of tolerance, and ensures the accuracy and safety of the welding process.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of steel structure welding, more particularly, it is a kind of steel structure installation welding auxiliary positioning device. BACKGROUND

[0002] In the process of steel structure installation in power plant, welding is the main way to connect steel structure components, however, due to the fact that steel structure components are usually bulky, heavy and have various shapes, accurate positioning and fixing of these components during welding becomes a technical problem. In the prior art, in order to ensure the welding quality, special clamps and support structures are needed to stabilize the components to prevent deformation during welding.

[0003] The existing part of steel structure installation welding auxiliary positioning device has deficiencies in precision and stability. Due to errors in design or manufacturing process, the device has deviation when positioning, which affects the accuracy and consistency of welding.

[0004] Therefore, a new scheme is needed to solve this problem. SUMMARY

[0005] In view of the deficiencies of the prior art, the purpose of the present application is to provide a steel structure installation welding auxiliary positioning device, which has the advantages of improving the precision and stability of steel structure during welding.

[0006] The above technical purpose of the present application is realized by the following technical scheme: a steel structure installation welding auxiliary positioning device, comprising: a base and a column, the base is internally provided with a plurality of detachable counterweight chassis, and the bottom is provided with anti-skid patterns and anchoring interfaces, suitable for temporary fixing on a platform, and the column is erected at the center of the base through a hydraulic elevator; a clamping mechanism located on the column for fixing the component to be welded; a laser ranging module integrated on the outside of the clamping mechanism, containing at least four groups of laser emitters in spatial orthogonal distribution, the four groups of laser emitters constitute a spatial positioning matrix, the deflection angle of the component is calculated by triangulation method, the three-dimensional spatial coordinates of the component and the target installation point are collected in real time, and a dynamic environment compensation unit is provided to eliminate the interference of welding smoke on the ranging accuracy; The dynamic environment compensation unit includes an infrared waveband filter and a pulse synchronizer, the infrared waveband filter filters out the 600-900nm interference spectrum generated by the welding arc, and the pulse synchronizer communicates with the welding control system to avoid the laser emission period from the strong light pulse of the arc; a controller, which is internally provided with an industrial PLC and a welding deformation prediction algorithm module, is used to receive the three-dimensional coordinate data of the laser ranging module and perform the following operations: Based on a preset welding deformation database and a finite element thermal force coupling model, an expected welding deformation amount is calculated, and a welding thermal deformation pre-compensation instruction is generated; The output positioning correction signal drives the clamping mechanism to adjust the pose of the component; The clamping pressure and positioning accuracy of the clamping mechanism are monitored in real time, and an out-of-tolerance alarm is triggered.

[0007] The welding deformation prediction algorithm module is further provided to perform the following steps: The component material, groove form and heat input parameters in the historical welding database are called; The expected deformation amount Delta L is calculated based on the finite element thermal force coupling model; The pre-compensation instruction is outputted to make the component offset in the opposite direction by Delta L times k, wherein k is a correction coefficient, and the value range is 0.9-1.1.

[0008] The dynamic environment compensation unit further comprises an air curtain generator, which forms a compressed air barrier to block smoke and dust at the laser emitter port.

[0009] The clamping mechanism comprises a cross beam and a hydraulic clamping jaw, the cross beam is longitudinally slidably connected to the stand, and the hydraulic clamping jaw is transversely slidably connected to the cross beam through a connecting piece.

[0010] The connecting piece comprises a mounting seat slidably connected to the surface of the cross beam and a spherical hinge bearing, the hydraulic clamping jaw is arranged on the surface of the spherical hinge bearing, a rubber pad is arranged on the hydraulic clamping jaw, and the rubber pad has high-temperature resistance.

[0011] The hydraulic clamping jaw is integrated with a pressure sensor, the pressure sensor is signal-connected to a controller, and the controller dynamically adjusts the clamping force of the hydraulic clamping jaw according to a preset pressure threshold and real-time feedback pressure.

[0012] The surface of the spherical hinge bearing is provided with a positioning disc with an angle sensor.

[0013] A dust cover is detachably connected to the outside of the laser emitter.

[0014] In summary, the present application has the following advantages: 1. During installation, the anchor can be inserted into the anchor interface to make the base firm and improve the safety of welding operation. The stand is vertically arranged at the center of the base through a hydraulic elevator, and the length of the stand can be adjusted according to the height of the welding operation position, so as to adapt to different operation conditions. 2、The existence of the dynamic environment compensation unit can guarantee that the laser emitter is not affected by high temperature and strong light during the welding process, and improves the accuracy of the collected spatial coordinates. 3、The PLC controller generates a pre-compensation amount through a welding deformation prediction algorithm module, and then adjusts the pose of the hydraulic clamping jaw according to the laser ranging data through PID control, while monitoring parameters such as clamping pressure and positioning accuracy in real time, and triggering an alarm and protection mechanism when the parameters are out of tolerance, thereby ensuring the accuracy and safety of the welding process. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a structural schematic diagram of the present application; Figure 2 is an enlarged view of A in Figure 1 Figure 3 is a sectional view of the present application; Figure 4 is a flowchart of the operation of the present application; Figure 5 is a flowchart of the calculation method of the correction coefficient in the present application.

[0016] In the figure: 1, base; 2, stand; 3, counterweight base; 4, anchoring interface; 5, hydraulic elevator; 6, laser emitter; 7, controller; 8, cross beam; 9, hydraulic clamping jaw; 10, mounting seat; 11, spherical hinge bearing; 12, rubber pad; 13, positioning disc; 14, dust cover. DETAILED DESCRIPTION

[0017] In order for those skilled in the art to better understand the technical solutions of the present application, the present application will be described in further detail below in combination with the drawings and specific embodiments, and it should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0018] In the description of the present application, it should be noted that the terms "upper", "lower", "inner", "outer", "top / bottom end" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0019] ​In the description of the present application, it should be noted that unless otherwise expressly specified and limited, the terms "mounting", "provided with", "sleeved / connected", "connected" and the like should be interpreted broadly, for example, "connected" can be fixedly connected, or detachably connected, or integrally connected; can be mechanically connected, or electrically connected; can be directly connected, or indirectly connected through an intermediate medium, or can be internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0020] A steel structure installation welding auxiliary positioning device, as shown in Figures 1-5 The base 1 is internally provided with a plurality of detachable counterweight bases 3, and the bottom is provided with anti-skid patterns and anchoring interfaces 4, which are suitable for temporary fixing of the platform. When it is necessary to build a welded steel frame in the power plant, the base 1 can be moved to the welding operation position, and then the counterweight bases 3 of equal weight are placed at the four corners of the base 1 to prevent the device from falling during operation. The anti-skid patterns can prevent the base 1 from sliding. During installation, the anchoring piece can be inserted into the anchoring interface 4 to make the base 1 firmly installed, thereby improving the safety of the welding operation. The stand 2 is vertically arranged at the center of the base 1 through a hydraulic elevator 5. According to the height of the welding operation position, the length of the stand 2 can be adjusted to adapt to different operation conditions.

[0021] The clamping mechanism is located on the stand 2 and slides for fixing the to-be-welded component. The clamping mechanism includes a cross beam 8 and a hydraulic clamping jaw 9. The cross beam 8 forms a longitudinal sliding pair with the stand 2 through a linear guide rail. The hydraulic clamping jaw 9 is transversely and slidably connected to the cross beam 8 through a connecting piece. The connecting piece includes a mounting seat 10 slidably connected to the surface of the cross beam 8 and a spherical hinge bearing 11. The mounting seat 10 is an electric sliding table that drives the hydraulic clamping jaw 9 to slide on the surface of the cross beam 8. The hydraulic clamping jaw 9 is arranged on the surface of the spherical hinge bearing 11. A rubber pad 12 is arranged on the hydraulic clamping jaw 9. The rubber pad 12 has high-temperature resistance and can adapt to the high temperature generated by the component during welding. A pressure sensor is integrated on the hydraulic clamping jaw 9. The signal of the pressure sensor is connected to a controller 7. The controller 7 dynamically adjusts the clamping force of the hydraulic clamping jaw 9 according to the preset pressure threshold and the real-time feedback pressure. A positioning disc 13 with an angle sensor is arranged on the surface of the mounting seat 10, which can monitor the plane deflection angle of the hydraulic clamping jaw 9.

[0022] In one embodiment, the hydraulic clamping jaw 9 is integrated with a laser ranging module on one side of the component, including at least four groups of laser emitters 6 arranged in a spatial orthogonal distribution, which constitute a spatial positioning matrix, simultaneously irradiating the target to be welded and the component itself, calculating the component deflection angle by triangulation method, real-time acquisition of three-dimensional spatial coordinates of the component and target mounting point, and having a dynamic environment compensation unit for eliminating the interference of welding smoke on the ranging accuracy. The presence of the dynamic environment compensation unit can ensure that the laser emitters 6 are not affected by high temperature and strong light during welding, improving the accuracy of acquiring spatial coordinates.

[0023] The dynamic environment compensation unit includes an infrared waveband filter and a pulse synchronizer. The infrared waveband filter filters out the 600-900 nm interference spectrum generated by the welding arc, and the pulse synchronizer communicates with the welding control system to make the laser emission period avoid the arc light pulse. The wavelength of the laser emitter 6 is about 905 nm. During welding, the infrared waveband filter can block the red light and near-infrared light generated by the welding arc, allowing the laser signal to be emitted. The pulse synchronizer can receive the frequency band of the arc light pulse, so that the laser emission can be staggered with the strong light pulse frequency band to prevent the laser emitter 6 from being disturbed.

[0024] The pulse synchronizer establishes a communication connection with the welding control system, and the synchronization control logic is as follows: Step one, the pulse synchronizer acquires the welding start-stop signal of the welding control system or the arc voltage pulse waveform of the welding power source in real time through the digital input module or the industrial communication bus as the synchronization reference signal.

[0025] Step two, the pulse synchronizer built-in microprocessor or programmable logic device performs hardware edge detection or software filtering and debouncing on the collected reference signal to accurately identify the starting point of each arc pulse. Considering the inherent delay of system communication and processing, the processor will automatically calculate and insert a preset delay amount after identifying the starting point of the arc pulse. The delay amount ensures that the laser emission window completely avoids the duration of the arc light and falls in the intermittent or stable period of the arc energy.

[0026] Step three, after delay processing, the pulse synchronizer sends a pulse width adjustable trigger pulse signal to the laser emitter 6 through the digital output module or the direct drive circuit. The trigger signal controls the laser emitter 6 to emit in the accurately calculated time window, and adds the duration of single laser emission at the time window, thereby achieving active peak avoidance between the laser emission period and the arc light pulse in time.

[0027] In one embodiment, the dynamic environment compensation unit further comprises an air curtain generator capable of spraying a ring of high-speed compressed air around the laser emission port to form a compressed air barrier to block the smoke generated during the welding process.

[0028] A dust cover 14 is further provided outside the laser emitter 6, which is made of quartz glass with strong light transmission. The presence of the dust cover 14 can prevent the smoke from directly covering the laser emitter 6.

[0029] In one embodiment, the controller 7 adopts an industrial programmable logic controller (PLC, model such as Siemens S7-1200), the core functions of which are realized through a modular program. The key processes include welding deformation prediction and compensation, pose closed-loop control, and multi-parameter real-time monitoring and protection, which are as follows: Welding deformation prediction algorithm module. This module realizes accurate compensation by fusing process parameters and simulation models, and the process is as follows: Data input stage. The operator enters the current welding key parameters through the human-machine interface, including component material, groove form, and heat input parameters. After receiving the parameters, the system automatically searches the historical welding database to match the case, and simultaneously starts the finite element thermal coupling simulation. By solving the heat conduction equation and structural mechanics equation, the expected deformation ΔL (unit: mm) is calculated and output.

[0030] The heat conduction analysis is based on Fourier's law and the law of conservation of energy, and its control equation is: ; Where ρ is the material density, c is the specific heat capacity, k is the thermal conductivity, T is the temperature, t is the time, and Q is the welding heat source input (such as Gaussian heat source, double-ellipsoid heat source, etc.).

[0031] The structural mechanics analysis is based on the elastic-plastic theory, which solves the stress and deformation generated under the action of the temperature field (as a volume load). Its balance equation, geometric equation, and constitutive relation (considering the effect of temperature on material properties, such as yield strength and elastic modulus) together form the basis for solving, and the final deformation ΔL is calculated.

[0032] The finite element thermal coupling simulation is completed by calling the calculation kernel of commercial finite element analysis software (such as ANSYS, ABAQUS, or MSC.Marc).

[0033] The interaction between the controller 7 (PLC) and the simulation software is realized through the application programming interface (API) or script file (such as Python script). The specific process is as follows: the PLC automatically generates the input file required for simulation (or passes the parameters through the API) based on the received process parameters (material, groove, heat input), then automatically calls the simulation software to perform calculation, and finally extracts the expected deformation ΔL from the simulation result file.

[0034] The specific process is as follows: Step one: Map the "component material" input by the human-machine interface into the specific parameters (density, specific heat, thermal expansion coefficient, etc.) of the material attribute library in the simulation model.

[0035] Step two: Select the preset finite element grid model according to the "groove form".

[0036] Step three: Calculate and define the heat source model parameters (such as power, efficiency, and heat source distribution parameters) according to the "heat input parameters".

[0037] Step four: Submit the task to the finite element solver for transient calculation.

[0038] Step five: After the calculation is completed, read the displacement results on the specified nodes or paths as ΔL.

[0039] Further, to improve the compensation accuracy, a correction coefficient k is introduced, and its engineering determination method is as follows: ; In the formula, the basic coefficient =1.0 (corresponding to the material thermal expansion coefficient ; the groove correction coefficient is valued according to the type (V-shaped groove =1.05, U-shaped groove =0.97); the plate thickness correction coefficient is determined according to the thickness (when the plate thickness is greater than 30mm, =1.05, otherwise take 1.0), and the final k value is limited to the interval of 0.9-1.1.

[0040] For example: weld a 31mm thick, V-shaped groove steel plate, k=1.0+0.05=1.05, and because the plate thickness is greater than 30mm, 1.05*1.05≈1.08, so the value calculated (ΔL×k) is the final pre-compensation instruction determined by the computer.

[0041] The output positioning correction signal drives the clamping mechanism to adjust the component pose. The PLC receives the three-dimensional coordinate data collected by the laser ranging module in real time, with a sampling period of 100ms, and fuses and analyzes it with the pre-compensation amount to generate a pose correction signal. Through the PID control algorithm, the hydraulic actuator is driven to realize three-degree-of-freedom accurate adjustment, i.e., longitudinal and transverse sliding positioning and angular deflection of the spherical bearing 11, to ensure that the component pose always meets the welding requirements.

[0042] The controller 7 monitors the clamping pressure and positioning accuracy of the clamping mechanism in real time, triggers an out-of-tolerance alarm, triggers an audible and light alarm when the clamping pressure deviates from the set range value, and locks the hydraulic system. When the laser ranging module detects that the displacement deviation or angle deviation of the hydraulic clamping jaw 9 is too large, the welding process is immediately paused to ensure the safety of the device operation and the welding quality.

[0043] Working principle: The column 2 is adjusted in height by the hydraulic elevator 5 to adapt to the operation demand through the counterweight chassis 3, anti-skid pattern and anchoring interface 4 fixation. The clamping mechanism relies on the cross beam 8 linear guide rail and electric sliding table to realize longitudinal and lateral movement. The hydraulic clamping jaw 9 adjusts the angle through the spherical hinge bearing 11, and the rubber pad 12 is resistant to high temperature. The pressure sensor linkage controller 7 dynamically adjusts the clamping force, and the positioning disc 13 monitors the deflection angle in real time. Four groups of space orthogonal laser emitters 6 form a positioning matrix, combined with infrared filter to filter out arc interference, pulse synchronizer to stagger strong light frequency, and air curtain to block smoke and dust to accurately collect three-dimensional coordinates. The dust cover 14 protects the laser emitter 6. The PLC controller 7 is the core, which generates a pre-compensation amount through a welding deformation prediction algorithm module, and then adjusts the pose of the clamping jaw according to the laser ranging data through PID control. At the same time, it monitors parameters such as clamping pressure and positioning accuracy in real time, and triggers an alarm and protection mechanism when it is out of tolerance, ensuring the accuracy and safety of the welding process.

[0044] The above is only the preferred embodiment of the present application, and the protection scope of the present application is not limited to the above-mentioned embodiments. Any technical solution falling within the scope of the present application is within the protection scope of the present application. It should be noted that for ordinary skilled persons in the art, some improvements and refinements without departing from the principles of the present application are also considered within the protection scope of the present application.

Claims

1. A steel structure installation welding auxiliary positioning device, characterized in that, include: The base and the column are provided. The base is equipped with several detachable counterweight base plates and has anti-slip texture and anchoring interface on the bottom, which is suitable for temporary platform fixation. The column is erected at the center of the base by a hydraulic lift. The clamping mechanism, which slides on the column, is used to fix the component to be welded; The laser ranging module is integrated on the outside of the clamping mechanism and includes at least four sets of laser emitters that are spatially orthogonally distributed. The four sets of laser emitters form a spatial positioning matrix. The deflection angle of the component is calculated by triangulation, and the three-dimensional spatial coordinates of the component and the target installation point are collected in real time. It also has a dynamic environmental compensation unit to eliminate the interference of welding fumes on the ranging accuracy. The dynamic environment compensation unit includes an infrared band filter and a pulse synchronizer. The infrared band filter filters out the 600-900nm interference spectrum generated by the welding arc. The pulse synchronizer communicates with the welding control system to ensure that the laser emission cycle avoids the strong light pulse of the arc. The controller, with a built-in industrial PLC and welding deformation prediction algorithm module, receives three-dimensional coordinate data from the laser ranging module and performs the following operations: Based on a pre-set welding deformation database and a finite element thermo-mechanical coupling model, the expected welding deformation is calculated, and a welding thermal deformation pre-compensation instruction is generated. The output positioning and correction signal drives the clamping mechanism to adjust the position and orientation of the component. The clamping pressure and positioning accuracy of the clamping mechanism are monitored in real time, and an out-of-tolerance alarm is triggered.

2. The auxiliary positioning device for steel structure installation and welding according to claim 1, characterized in that: The welding deformation prediction algorithm module performs the following steps: Call the component material, bevel type, and thermal input parameters from the historical welding database; The expected deformation ΔL is calculated based on the finite element thermo-mechanical coupling model. Output a pre-compensation command to cause the component to pre-offset in the opposite direction by ΔL×k, where k is a correction coefficient with a value range of 0.9-1.

1.

3. The auxiliary positioning device for steel structure installation and welding according to claim 1, characterized in that: The dynamic environmental compensation unit also includes an air curtain generator, which forms a compressed air barrier at the laser emission port to block smoke and dust.

4. The auxiliary positioning device for steel structure installation and welding according to claim 1, characterized in that: The clamping mechanism includes a crossbeam and hydraulic grippers. The crossbeam is longitudinally slidably connected to the column, and the hydraulic grippers are laterally slidably connected to the crossbeam via a connector.

5. The auxiliary positioning device for steel structure installation and welding according to claim 4, characterized in that: The connector includes a mounting base and a ball joint bearing that are slidably connected to the surface of the crossbeam. The hydraulic gripper is disposed on the surface of the ball joint bearing and is provided with a rubber pad. The rubber pad has high temperature resistance.

6. The auxiliary positioning device for steel structure installation and welding according to claim 4, characterized in that: The hydraulic gripper is equipped with a pressure sensor, and the pressure sensor signal is connected to the controller. The controller dynamically adjusts the clamping force of the hydraulic gripper according to the preset pressure threshold and the real-time feedback pressure.

7. The auxiliary positioning device for steel structure installation and welding according to claim 5, characterized in that: The ball joint bearing surface is provided with a positioning disk with an angle sensor.

8. The auxiliary positioning device for steel structure installation and welding according to claim 1, characterized in that: The laser emitter is detachably connected to a dust cover.

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