Intelligent production line and production method for ultra-long heavy welded H-shaped steel

Abstract

The embodiment of the invention provides a super-long heavy welding H-shaped steel intelligent production line and a production method, and relates to the field of steel structure manufacturing. The invention aims to solve the problems of low production efficiency, poor product precision and quality consistency and high safety risk caused by the fact that a traditional heavy H-shaped steel production line highly depends on manual operation and travelling crane hoisting. The production line comprises groove machining equipment, jointed board welding equipment, batten cutting equipment, abutted seam correcting equipment, polishing and chamfering equipment, H-shaped steel assembling equipment, H-shaped steel welding forming equipment, wing plate correcting equipment, welding seam detecting equipment and fixed-length cutting equipment which are sequentially arranged in the material flowing direction. By integrating an automatic logistics system and an MES production management system, the processes of groove machining, jointed board welding, batten cutting, assembling, welding, correcting, detecting, cutting and the like are seamlessly connected. Manual intervention and travelling crane hoisting are greatly reduced, and the full penetration of the welding seam and the correction precision of the wing plate are ensured through the technologies of laser tracking, intelligent correction, phased array detection and the like.

Description

Technical Field

[0001] This invention relates to the field of steel structure manufacturing, and more specifically, to an intelligent production line and method for ultra-long heavy-duty welded H-beams. Background Technology

[0002] In the steel structure manufacturing industry, especially in the production of heavy equipment such as quay cranes, H-beams are key load-bearing components. Their manufacturing process and production efficiency directly determine the structural strength, dimensional accuracy, and market competitiveness of the products. However, current traditional heavy-duty H-beam production lines have significant drawbacks: production equipment is generally outdated, automation and informatization levels are low, and there is a heavy reliance on manual operation and overhead cranes for material transfer and process connection (covering cutting, assembly, welding, turning, and straightening). This not only leads to high labor costs and prominent safety risks, but also results in long production line cycles and low efficiency due to the separate operation of each process (such as the need for multiple manual turnings for plate welding, and the separation of cutting and assembly). At the same time, the loose production process and a large amount of manual intervention make it difficult to guarantee the dimensional accuracy and weld quality consistency of products (especially ultra-long components), failing to meet the stringent requirements of high-end heavy equipment such as quay cranes for the strength and dimensional tolerances of load-bearing components. As companies in the industry accelerate the construction of automated production lines to enhance competitiveness, the traditional decentralized and inefficient production model has clearly lagged behind the needs of industry development. Summary of the Invention

[0003] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0004] The present invention aims to provide, for example, an intelligent production line and method for ultra-long heavy-duty welded H-beams, which can improve the problems of low production efficiency, poor product precision and quality consistency, and high safety risks caused by the low level of automation and informatization, high dependence on manual labor and overhead cranes in traditional heavy-duty H-beam production lines.

[0005] The embodiments of the present invention can be implemented as follows:

[0006] This invention provides an intelligent production line for ultra-long heavy-duty welded H-beams, comprising, sequentially arranged along the material flow direction, a beveling processing device, a plate welding device, a strip cutting device, a joint straightening device, a grinding and chamfering device, an H-beam assembly device, an H-beam welding and forming device, a flange straightening device, a weld inspection device, and a fixed-length cutting device. The beveling processing device is used to bevele both ends of the steel plates; the plate welding device is used to weld multiple steel plates into a large plate and perform double-sided submerged arc welding on the weld seam; the strip cutting device is used to cut the welded large plate into strips of the required specifications and perform beveling; the joint straightening device is used to correct deformation of the strip joints; and the grinding and chamfering device is used to straighten the strip joints. The cutting surfaces and assembly surfaces are ground and chamfered; the H-beam assembly equipment is used to assemble the web plate and two flanges into an H-beam using a "⊥-shaped → I-shaped" process; the H-beam welding and forming equipment is used to automatically weld the assembled H-beams in ship-shaped and all-position positions; the flange straightening equipment is used to perform high-precision straightening of the welded H-beam flanges; the weld inspection equipment is used to perform non-destructive testing and defect marking on the main welds of the H-beams; the fixed-length cutting equipment is used to cut the finished H-beams to a fixed length; the production line is managed by a Production Execution System (MES) with centralized monitoring and intelligent scheduling in the central control room; the various devices are connected through an automated logistics system to achieve fully automated material flow.

[0007] In addition, the intelligent production line for ultra-long heavy-duty welded H-beams provided in the embodiments of the present invention may also have the following additional technical features:

[0008] Optionally, the panel welding equipment includes a hydraulic key-type clamping device, a twin-wire submerged arc welding system, a plasma gouging device, and a panel flipping mechanism; the hydraulic key-type clamping device is used to apply distributed pressure to both sides of the weld; the twin-wire submerged arc welding system is equipped with a laser vision sensor for weld trajectory tracking; the plasma gouging device is used to perform root cleaning on the back of the weld; and the panel flipping mechanism is used to automatically flip large panels.

[0009] Optionally, the slab cutting equipment is a multi-head CNC flame cutting machine. The slab cutting equipment includes a linear cutting torch assembly, a beveling torch, and a CNC system. The linear cutting torch assembly is used to simultaneously cut multiple slabs; the beveling torch is used to complete beveling while cutting; and the CNC system is used to control the cutting path and beveling parameters.

[0010] Optionally, the seam straightening device includes a hydraulic straightener that moves up and down, wherein the hydraulic straightener uses a downward pressing method to straighten the seam.

[0011] Optionally, the H-beam assembly equipment includes a vertical assembly machine, a 90° web plate turning machine, and a 180° T-beam turning machine; the vertical assembly machine is used for precise alignment and assembly of the flange and web plate; the 90° web plate turning machine is used to turn the horizontally placed web plate into an upright position to complete the "⊥" welding of the flange and web plate; the 180° T-beam turning machine is used to turn the T-beam so that it can be assembled with another flange plate to form an "I" shape for welding.

[0012] Optionally, the H-beam welding and forming equipment includes multiple double-wire cantilever submerged arc welding machines, multiple 180° turning machines, multiple 55° welding frames, and a weld tracking system; the multiple double-wire cantilever submerged arc welding machines use welding wire for welding; the multiple 180° turning machines are used to turn the H-beam into a ship-shaped position; the multiple 55° welding frames are used to turn the H-beam into a ship-shaped welding state; the weld tracking system is used to automatically locate the weld start point and track the welding path.

[0013] Optionally, the wingplate straightening equipment includes a vertical straightening machine, a laser scanning measurement system, and a dynamic adjustment system; the vertical straightening machine is used to perform roller straightening on the upper and lower sides of the wingplate, the laser scanning measurement system is used to detect the deformation of the wingplate in real time, and the dynamic adjustment system is used to dynamically adjust the straightening parameters according to the detection results; wherein, the straightening accuracy reaches ≤1mm in the wingplate width direction.

[0014] Optionally, the weld inspection equipment includes a phased array ultrasonic flaw detector, a data analysis system, and a defect marking device; the phased array ultrasonic flaw detector is used to inspect four main welds; the data analysis system is used to generate inspection reports and quality archives based on the inspection results; and the defect marking device is used to accurately locate and mark non-conforming positions.

[0015] Optionally, the automated logistics system includes a conveyor roller conveyor and a truss-type KBK crane, wherein the total length of the conveyor roller conveyor is greater than or equal to 500 meters, and the number of truss-type KBK cranes is at least 3 sets.

[0016] Embodiments of the present invention also provide a method for producing ultra-long heavy-duty welded H-beams. Implemented using an intelligent production line for ultra-long heavy-duty welded H-beams, the method includes the following steps:

[0017] The raw steel plates are beveled, assembled at the splicing station, and the front and back sides are welded and cleaned to obtain large plates.

[0018] After the large plate is welded, it is cut into strips and beveled. Then the joints of the strips are straightened, and the cut surfaces and assembly surfaces of the strips are ground and chamfered.

[0019] The processed strips are assembled into H-beams using the method of "first assembling the ⊥ type, then assembling the I-type".

[0020] The assembled H-beams are then welded into a ship shape, and the flanges are straightened and the weld quality is inspected after welding.

[0021] The qualified H-beams are cut to length to obtain finished H-beams;

[0022] The method is managed by the Production Execution System (MES), monitored and scheduled by the central control room, and materials are automatically transferred between workstations through an automated logistics system.

[0023] The beneficial effects of the intelligent production line and production method for ultra-long heavy-duty welded H-beams according to embodiments of the present invention include, for example:

[0024] This intelligent production line for extra-long, heavy-duty welded H-beams includes beveling equipment, plate welding equipment, strip cutting equipment, joint straightening equipment, grinding and chamfering equipment, H-beam assembly equipment, H-beam welding and forming equipment, flange straightening equipment, weld inspection equipment, and fixed-length cutting equipment arranged sequentially along the material flow direction. The beveling equipment is used to bevele both ends of the steel plates; the plate welding equipment is used to weld multiple steel plates into a large plate and perform double-sided submerged arc welding on the weld seam; the strip cutting equipment is used to cut the welded large plate into strips of the required specifications and perform beveling; the joint straightening equipment is used to correct deformation of the strip joints; and the grinding and chamfering equipment is used to clean the cut surfaces of the strips and... The assembly surfaces are ground and chamfered; the H-beam assembly equipment is used to assemble the web plate and two flanges into H-beams using a "⊥-shaped → I-shaped" process; the H-beam welding and forming equipment is used to automatically weld the assembled H-beams in ship-shaped and all-position positions; the flange straightening equipment is used to perform high-precision straightening of the welded H-beam flanges; the weld inspection equipment is used to perform non-destructive testing and defect marking on the main welds of the H-beams; the fixed-length cutting equipment is used to cut the finished H-beams to length; the production line is managed by a Production Execution System (MES) for full-line information management, with centralized monitoring and intelligent scheduling in the central control room; the various equipment are connected through an automated logistics system to achieve fully automated material flow.

[0025] By integrating an automated logistics system with a MES production management system, processes such as beveling, plate welding, strip cutting, assembly, welding, straightening, inspection, and cutting are seamlessly connected, achieving fully automated and information-based production of ultra-long heavy H-beams from raw materials to finished products. This significantly reduces manual intervention and overhead crane operations, substantially improving production efficiency and product consistency. Simultaneously, technologies such as laser tracking, intelligent straightening, and phased array detection ensure full weld penetration, flange straightening accuracy, and quality traceability, fully meeting the high precision and high strength requirements of heavy equipment structural components.

[0026] The intelligent production method for ultra-long heavy-duty welded H-beams, implemented using the aforementioned production line, can improve the problems of low production efficiency, poor product precision and quality consistency, and high safety risks caused by the low level of automation and informatization, heavy reliance on manual labor and overhead cranes in traditional heavy-duty H-beam production lines. Attached Figure Description

[0027] The above-described features and advantages of the present invention will be better understood after reading the following detailed description of embodiments of the present disclosure in conjunction with the accompanying drawings. In the drawings, components are not necessarily drawn to scale, and components having similar related characteristics or features may have the same or similar reference numerals.

[0028] Figure 1 A schematic diagram of an intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0029] Figure 2 A schematic diagram of a flame beveling machine for an intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram of the splicing station of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0031] Figure 4 A schematic diagram of a multi-flame cutting machine for an intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0032] Figure 5 A schematic diagram of the loading gantry of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0033] Figure 6 A schematic diagram of hydraulic straightening of an intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0034] Figure 7 A schematic diagram of a grinding and chamfering machine for an intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0035] Figure 8 A schematic diagram of the assembly station of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0036] Figure 9 A schematic diagram of the H-beam forming and welding station of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0037] Figure 10 A schematic diagram of the wing plate straightening station of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0038] Figure 11A schematic diagram of the phased array weld inspection station of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention;

[0039] Figure 12 This is a schematic diagram of the section steel cutting station of the intelligent production line for ultra-long heavy-duty welded H-beams provided in an embodiment of the present invention.

[0040] Icons: 1-Beveling station; 2-Plate assembly station; 3-Strip cutting station; 4-Loading gantry station; 5-Joint straightening station; 6-Grinding and chamfering station; 7-H-beam assembly station; 8-H-beam forming and welding station; 9-Wing plate straightening station; 10-Phase array weld inspection station; 11-Steel section cutting station; 12-Central control room; 21-Welding input roller conveyor; 22-Plate assembly and welding equipment; 23-Welding output roller conveyor; 24-Plate flipping mechanism; 25-Plasma gouging; 71-⊥-shaped assembly roller conveyor; 72-Vertical assembly machine; 73-Assembly output roller conveyor; 74-90° web plate flipping machine; 75-180° T-beam flipping machine; 111-Cutting input roller conveyor; 112-Steel section cutting machine; 113-Cutting output roller conveyor; 114-Steel section pushing mechanism. Detailed Implementation

[0041] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0042] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," "outer," or "vertical" appear, the orientation or positional relationship indicated is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed when in use, and does not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0043] At the same time, it should be noted that the terms "first" and "second" are used only for distinguishing descriptions and should not be interpreted as indicating or implying relative importance.

[0044] In the description of this invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an integral connection, or a detachable connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or a connection within two components, etc. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0045] The following is combined Figures 1 to 12 The intelligent production line for ultra-long heavy-duty welded H-beams provided in this embodiment is described in detail.

[0046] Please refer to Figure 1 This invention provides an intelligent production line for ultra-long heavy-duty welded H-beams, comprising, in sequence along the material flow direction, a beveling equipment, a plate welding equipment 22, a strip cutting equipment, a joint straightening equipment, a grinding and chamfering equipment, an H-beam assembly equipment, an H-beam welding and forming equipment, a flange straightening equipment, a weld inspection equipment, and a fixed-length cutting equipment; the beveling equipment is used to bevele both ends of the steel plates; the plate welding equipment 22 is used to weld multiple steel plates into a large plate and perform double-sided submerged arc welding on the weld; the strip cutting equipment is used to cut the welded large plate into strips of the required specifications and perform beveling; the joint straightening equipment is used to correct the deformation of the strip joints; the grinding and chamfering equipment is used for... The cutting surfaces and assembly surfaces of the steel strips are ground and chamfered; the H-beam assembly equipment is used to assemble the web plate and two flanges into an H-beam using a "⊥-shaped → I-shaped" process; the H-beam welding and forming equipment is used to automatically weld the assembled H-beams in ship-shaped and all-position positions; the flange straightening equipment is used to perform high-precision straightening of the welded H-beam flanges; the weld inspection equipment is used to perform non-destructive testing and defect marking on the main welds of the H-beams; the fixed-length cutting equipment is used to cut the finished H-beams to a fixed length; the production line is managed by a Production Execution System (MES) for full-line information management, and is centrally monitored and intelligently scheduled by the central control room; the various equipment are connected through an automated logistics system to achieve fully automated material flow.

[0047] Along the material flow direction, the following stations are arranged in sequence: beveling station 1, plate assembly station 2, strip cutting station 3, loading gantry station 4, joint straightening station 5, grinding and chamfering station 6, H-beam assembly station 7, H-beam forming and welding station 8, wing plate straightening station 9, and phased array weld inspection station 10.

[0048] The beveling equipment is set at beveling station 1; the plate welding equipment 22 is set at plate assembly station 2; the strip cutting equipment is set at strip cutting station 3; the joint straightening equipment is set at joint straightening station 5; the grinding and chamfering equipment is set at grinding and chamfering station 6; the H-beam assembly equipment is set at H-beam assembly station 7; the H-beam welding and forming equipment is set at H-beam forming and welding station 8; the wing plate straightening equipment is set at wing plate straightening station 9; and the weld inspection equipment is set at phased array weld inspection station 10.

[0049] By replacing overhead cranes with automated logistics systems, uninterrupted and continuous material flow is achieved; by merging processes with integrated processing equipment, turnaround time is reduced; and by having multiple devices work in parallel, production line cycle time is significantly shortened. Intelligent process equipment, such as laser-tracking welding and adaptive correction, replaces manual experience and eliminates human error; the step-by-step assembly process from ⊥ to I-beam reduces the difficulty of assembling ultra-long workpieces; and online automatic inspection achieves 100% quality monitoring, ensuring that all output products meet stringent standards. Full-process automation frees workers from heavy manual labor and high-risk operations, reducing safety risks, dependence on skilled workers, and optimizing labor costs.

[0050] Reference Figure 2 In this embodiment, at the beveling station 1, flame cutting is used to bevele both ends of the raw material to ensure that subsequent welding meets quality requirements. Specifically, the beveling equipment is located at the front end of the production line. A CNC system precisely controls the angle and position of the cutting torch to cut a bevel shape (such as V-shape or K-shape) that meets welding requirements at the end of the steel plate. This provides a qualified welding interface for subsequent plate assembly welding processes, ensuring that the weld achieves full penetration.

[0051] Reference Figure 3 In this embodiment, the panel welding equipment 22 includes a hydraulic key-type clamping device, a twin-wire submerged arc welding system, a plasma gouging device 25, and a panel flipping mechanism 24; the hydraulic key-type clamping device is used to apply distributed pressure to both sides of the weld; the twin-wire submerged arc welding system is equipped with a laser vision sensor to track the weld trajectory; the plasma gouging device 25 is used to perform root cleaning on the back of the weld; and the panel flipping mechanism 24 is used to automatically flip large panels.

[0052] At panel assembly station 2, a panel assembly machine, two sets of automatic panel welding machines, a reverse-side carbon planer (plasma carbon planer), an automated roller conveyor system, and a panel flipping mechanism (total panel flipping weight 25 tons) are configured. Full penetration of the panel weld is achieved using a combination of front-side submerged arc welding, flipping plasma gouging (25 tons), and reverse-side submerged arc welding. After the workpiece enters the panel pressure frame, the weld is moved to the center line of the copper plate via a servo roller conveyor. The hydraulic key system of the pressure frame is then activated to hold the steel plate in place, and the submerged arc welding system is started for automatic welding. During the welding process, the weld is tracked in real-time by a laser automatic tracking system.

[0053] Specifically, the piano-key type uses multiple independently adjustable hydraulic pressure blocks to apply pressure evenly along the entire length of the weld, maximizing the suppression of welding thermal deformation. In the dual-wire submerged arc welding, the front wire uses a high current to ensure penetration, while the rear wire uses a low current to refine the weld shape, resulting in high efficiency and high quality. After welding the front side, the plasma gouging 25 flips the workpiece and uses a plasma arc to quickly and precisely remove the back weld roots, ensuring the quality of the reverse side welding. Laser tracking detects and compensates for weld trajectory deviations caused by thermal deformation or gaps between joints in real time. Welding input rollers 21 and welding output rollers 23 are respectively installed before and after the panel welding equipment 22.

[0054] The double-arc, double-wire automatic submerged arc welding technology is adopted, and the hydraulic key pressure block is used to rigidly fix both sides of the weld to completely suppress welding thermal deformation. The welding process is calibrated in real time by a laser automatic tracking system, and the reverse side is cleaned by plasma gouging 25 to ensure full penetration of the weld.

[0055] Reference Figure 4 In this embodiment, the slab cutting equipment is a multi-head CNC flame cutting machine. The slab cutting equipment includes a linear cutting torch group, a beveling torch, and a CNC system. The linear cutting torch group is used to complete the cutting of multiple slabs simultaneously; the beveling torch is used to complete the beveling process while cutting; and the CNC system is used to control the cutting path and beveling parameters.

[0056] A flame cutting machine (straight cutting + beveling) integrated forming machine is configured at plate cutting station 3. The main unit has a gauge of 3500mm and an actual cutting length of 25000mm. It is equipped with twelve sets of CNC linear cutting torch devices, three sets of rear beam double cutting torch devices (beveling), and a CNC system. According to production needs, the CNC system can control the cutting torch devices to perform multiple cuts, beveling, and cross-cutting on the steel plate, achieving precise steel plate cutting.

[0057] Equipped with a multi-head automatic adjustment CNC flame cutting machine, the separate beveling process is eliminated, directly realizing integrated cutting and beveling processing, thus improving overall efficiency.

[0058] Reference Figure 5 In this embodiment, a loading gantry station 4 is also provided between the strip cutting station 3 and the seam straightening station 5. At the loading gantry station 4, permanent magnet chucks are used to automatically lift the cut strips onto the seam straightening input roller conveyor.

[0059] Reference Figure 6 In this embodiment, the seam straightening device includes a hydraulic straightener that moves up and down. The hydraulic straightener uses a downward pressing method to straighten the seam.

[0060] At the joint straightening station 5, a hydraulic (downward) straightening method is used to straighten the joints and ensure the overall flatness of the panels.

[0061] Reference Figure 7 In this embodiment, the grinding and chamfering station 6 mainly grinds the primer on the assembly surface of the cut strips and the cut surfaces at both ends to ensure the assembly accuracy of the subsequent assembly. The four corners on both sides of the wing plate are chamfered, requiring the rounded corners to be R2±0.5mm to ensure that the subsequent paint can adhere effectively and is not easy to fall off.

[0062] Reference Figure 8 In this embodiment, the H-beam assembly equipment includes a vertical assembly machine 72, a 90° web plate turning machine 74, and a 180° T-beam turning machine 75; the vertical assembly machine 72 is used for precise alignment and assembly of the flange and the web plate; the 90° web plate turning machine 74 is used to turn the horizontally placed web plate into an upright state to complete the "⊥" welding of the flange and the web plate; and the 180° T-beam turning machine 75 is used to turn the T-beam so that it can be assembled with another flange plate to form an "I" shape for welding.

[0063] At the H-beam assembly station 7, the first wing plate is automatically and horizontally lifted onto the input roller conveyor of the assembly machine using a loading gantry (KBK). The web plate is then lifted onto the web plate rack using the loading gantry. The pre-assembly of the ⊥-shaped steel is achieved through an automatic wing plate centering device and a 90-degree automatic web plate flipping device, and then fed into the assembly machine for automatic assembly. The ⊥-shaped steel output from the assembly is rotated 90 degrees by a 180-degree flipping machine and then moved laterally to the return roller conveyor by a lifting and transferring machine. It is then moved to the T-beam flipping platform by the lifting and transferring machine. The second wing plate is automatically and horizontally lifted onto the input roller conveyor of the assembly machine using a loading gantry. The pre-assembly of the H-beam is achieved through an automatic wing plate centering device and a 90-degree automatic T-beam flipping device, and then fed into the assembly machine for automatic assembly. A ⊥-shaped steel assembly roller conveyor 71 and an assembly output roller conveyor 73 are respectively installed before and after the vertical assembly machine 72.

[0064] The vertical assembly machine 72, equipped with a circulating storage device and a transfer trolley, enables automatic stacking of wing plates and web plates. A moving device transports the entire stack of plates to the assembly station, employing a step-by-step assembly process from "⊥-shaped → I-shaped" to ensure the positioning accuracy of ultra-long components. The complex problem of simultaneously aligning three plates (two wing plates and one web plate) is simplified to aligning only two plates in two steps, significantly improving the assembly accuracy and efficiency of ultra-long heavy H-beams and guaranteeing the final product's dimensional and positional tolerances.

[0065] Reference Figure 9 In this embodiment, the H-beam welding and forming equipment includes multiple double-wire cantilever submerged arc welding machines, multiple 180° turning machines, multiple 55° welding frames, and a weld tracking system. The multiple double-wire cantilever submerged arc welding machines use welding wire for welding. The multiple 180° turning machines are used to turn the H-beam into its ship-shaped position. The multiple 55° welding frames are used to turn the H-beam into its ship-shaped welding state. The weld tracking system is used to automatically locate the weld start point and track the welding path.

[0066] After the eight pairs of assembled H-beams are formed at the H-beam forming and welding station, they are moved to the 55° rotating frame on the cantilever double-wire submerged arc welding station with the assistance of a steel transfer machine and roller conveyor. When the frame is rotated to the ship-shaped welding position, the submerged arc welding machine uses laser weld seam tracking to locate the weld seam starting position, automatically initiates the arc, automatically feeds the material, automatically terminates the arc, and automatically shuts off the flux supply in advance. The entire process requires no manual intervention.

[0067] Equipped with 6 twin-wire cantilever submerged arc welding machines + 3 180° tilting machines + 6 55° welding frames, supporting Φ

[0068] 3-Φ5mm welding wire; by using a rotating machine and welding frame in combination at multiple angles, ship-shaped welding and all-position welding can be achieved, increasing welding efficiency by 50%.

[0069] Reference Figure 10 In this embodiment, the wingplate straightening equipment includes a vertical straightening machine, a laser scanning measurement system, and a dynamic adjustment system. The vertical straightening machine is used to perform roller straightening on the upper and lower sides of the wingplate. The laser scanning measurement system is used to detect the deformation of the wingplate in real time. The dynamic adjustment system is used to dynamically adjust the straightening parameters according to the detection results. The straightening accuracy reaches ≤1mm in the wingplate width direction.

[0070] Nine pairs of welded H-beams at the flange straightening station are transported to the straightening machine with the assistance of a steel transfer machine and roller conveyor. This process corrects welding deformation in the flanges using laser scanning and automatic adjustment of the straightening amount, requiring the flange width direction to be ≤1mm.

[0071] To achieve high-precision control of the correction zone, two vertical correction machines are used, suitable for flange widths of 200-1000mm (thickness 6-60mm), web heights of 200-1500mm (thickness 6-40mm), and component lengths of 4000-20000mm; the correction speed is 2.8-5.6m / min, and the high-end model integrates a laser real-time detection system to dynamically adjust the correction amount with an accuracy of ±0.5mm.

[0072] Reference Figure 11 In this embodiment, the weld inspection equipment includes a phased array ultrasonic flaw detector, a data analysis system, and a defect marking device; the phased array ultrasonic flaw detector is used to inspect four main welds; the data analysis system is used to generate inspection reports and quality files based on the inspection results; and the defect marking device is used to accurately locate and mark non-conforming positions.

[0073] At the phased array weld inspection station, automatic ultrasonic testing (UT) is performed on the four main welds of the H-beams after flange straightening. Defective areas are automatically marked, significantly improving the efficiency and accuracy of the inspection. Equipped with two phased array flaw detectors, the system automatically analyzes weld quality and generates reports, accurately marking defect locations and supporting rapid rework.

[0074] Reference Figure 12 In this embodiment, the head of the straightened H-beam is cut at the H-beam cutting station 11. This process mainly consists of two parts: a robot cutting station control system bus and an automatic profile loading / unloading system. The actions of each execution unit are completed through program instructions and PLC signal transmission. The automatic loading / unloading control part mainly consists of a PLC, a human-machine interface, a hydraulic control system, an AC motor, and external sensors. Combined with mechanical transmission, the logic control of each execution unit is completed through PLC internal programming, meeting the requirements of the on-site environment and facilitating profile loading / unloading operations for operators. Two remote control operation stations and a human-machine interface are designed externally. A cutting input roller conveyor 111 and a cutting output roller conveyor 113 are respectively set before and after the profile cutting machine 112.

[0075] The fixed-length cutting equipment cuts H-beams in the cutting area, with a maximum cutting length of 20,000 mm and a maximum single weight of 6,000 kg. The processing range covers webs of 200-1300 mm and flanges of 200-800 mm, with a cutting thickness of 1-60 mm and a speed of 0-60 m / min, enabling fixed-length finished product output.

[0076] In this embodiment, the automated logistics system includes a conveyor roller conveyor and a truss-type KBK crane. The total length of the conveyor roller conveyor is greater than or equal to 500 meters, and the number of truss-type KBK cranes is at least 3 sets.

[0077] The production line is sequentially set up with a raw material preparation area → assembly area → cutting area → grinding and chamfering area → assembly area → welding area → straightening area → inspection area → storage area → H-beam cutting area. Each area is connected by a 500-meter conveyor roller conveyor + 3 sets of KBK trusses to form an automated logistics system, realizing fully automated material transfer, reducing crane usage time by more than 85%, and significantly reducing safety risks. The conveyor roller conveyor + KBK trusses enable seamless connection between processes, eliminating manual handling intervention.

[0078] Reference Figures 1 to 12 The present invention also provides a method for producing ultra-long heavy-duty welded H-beams. Implemented using an intelligent production line for ultra-long heavy-duty welded H-beams, the method includes the following steps:

[0079] Step S1: Beveling the raw material steel plate, assembling it at the assembly station 2, and welding and cleaning the front and back sides to obtain the large plate.

[0080] Step S2: Cut the welded large plate into strips and beveling them. Then, straighten the joints of the strips and grind and chamfer the cut surfaces and assembly surfaces of the strips.

[0081] Step S3: Assemble the H-beams by first assembling the strips into ⊥ shapes, then assembling the I-beams.

[0082] Step S4: Perform ship-shaped welding on the assembled H-beams, and then straighten the flanges and inspect the weld quality after welding.

[0083] Step S5: Cut the qualified H-beams to length to obtain the finished H-beams;

[0084] The method is managed by the Production Execution System (MES), monitored and scheduled in the central control room, and materials are automatically transferred between workstations through an automated logistics system.

[0085] It enables real-time monitoring of all equipment and production data, supporting capacity analysis, equipment management, quality control, and fault diagnosis; it also reserves an interface for a digital twin system, providing scalability for full lifecycle management. The production method for ultra-long heavy-duty welded H-beams defines a continuous, efficient, high-quality, and replicable standardized production process, ensuring that every step from raw materials to finished products is under control, ultimately producing ultra-long heavy-duty H-beams that meet the stringent requirements of heavy equipment such as quay cranes.

[0086] In this embodiment, the Manufacturing Execution System (MES) is used to display the operating status and condition of equipment, such as running, stopped, faulty, and alarm. It can analyze and display the operating status of equipment more quickly and accurately. At the same time, it can collect data on the status of each workstation, processing information, operating status information, consumable information, and production line energy consumption information. The collected data is stored in the server database, recording the information data of each major workstation, and can interface with the upper-level workshop management system. It has an interactive data interface with the upper-level management system, providing the upper-level management system with production line operation-related data in real time, meeting the enterprise's needs for production line information management.

[0087] In this embodiment, the central control room 12 is equipped with two sets of i7 or higher-level operator machines, a COB three-in-one LED screen with specific parameters, and a three-section stainless steel dispatch console. Servers are provided as needed. The system must support remote control, intelligent scheduling, and data-driven decision-making, meeting corresponding response time requirements. This allows the production line to be remotely controlled from the central control room 12 during operation, significantly reducing personnel input and effectively improving production line efficiency and capacity.

[0088] According to the intelligent production line for ultra-long heavy-duty welded H-beams provided in this embodiment, the specific implementation process of the intelligent production line for ultra-long heavy-duty welded H-beams includes:

[0089] In the material loading and assembly process, after the raw steel plates are beveled, they are loaded to the feeding area of ​​the assembly station 2 by the intelligent permanent magnet crane in the workshop. At the assembly station 2, the plates are assembled, welded (front submerged arc welding), flipped, plasma gouged 25 for root cleaning, and back submerged arc welding are performed to complete the complete assembly operation.

[0090] In the cutting and pre-processing process, the assembled panels are hoisted to the cutting station by an intelligent permanent magnet crane for cutting and beveling.

[0091] In the assembly and forming process, the cut plates are leveled by a leveling machine after being fed through a gantry and then conveyed to the grinding and chamfering station 6 to grind and chamfer the web plate and wing plate.

[0092] The processed web and flanges are transported to the assembly station and assembled into H-beams (first assembling the "⊥" shape, and finally the "I" shape).

[0093] In the welding and inspection process, the assembled H-beams are sent to the welding station via a logistics roller conveyor system for turning and welding. After welding, the H-beams are sent to the straightening station and straightened using a horizontal straightening machine to ensure that the width of the flange is ≤1mm. At the same time as the straightening, the phased array also uses an automatic ultrasonic flaw detection equipment to simultaneously inspect the weld.

[0094] In the finishing and blanking process, the qualified H-beams are conveyed to the profile cutting station by the steel transfer machine and roller conveyor for end cutting and connection hole processing; the finished H-beams are then unloaded by the existing overhead crane in the workshop, completing the entire production process.

[0095] The implementation method of the intelligent production line for ultra-long heavy-duty welded H-beams provided in this embodiment fully covers the intelligent production needs of ultra-long heavy-duty workpieces (length within 25m, single weight about 20 tons), and all parameters and process sequences are strictly set according to actual production verification.

[0096] The intelligent production line for ultra-long heavy-duty welded H-beams provided in this embodiment has at least the following advantages:

[0097] The ultra-long heavy-duty welded H-beam intelligent production line provided in this embodiment integrates efficient assembly, intelligent welding, automatic flipping and precise correction. It realizes intensive and collaborative processes, unmanned operation, and stable and controllable quality, and has become an urgent technical direction to solve the above pain points and enhance the core competitiveness of enterprises.

[0098] By integrating CNC cutting for "cutting and beveling" and integrating welding for "double-sided welding and root cleaning", the traditional separate beveling and root cleaning processes have been eliminated, significantly shortening the production process and improving overall efficiency.

[0099] The "⊥-shaped → I-shaped" intelligent step-by-step assembly process ensures the precision of ultra-long components, and the collaborative operation of multiple welding equipment and multi-angle flipping and repositioning equipment enables ship-shaped welding, thereby increasing welding efficiency by more than 50%.

[0100] The welding and straightening process integrates a laser tracking and scanning measurement system to achieve automatic tracking of weld seam trajectory and real-time feedback of deformation, dynamically adjust welding and straightening parameters, and ultimately control product accuracy at a high level of ±0.5mm.

[0101] The use of phased array ultrasonic flaw detection equipment enables automated and digital inspection of weld quality, automatically generates reports and marks defects, and establishes a quality data chain with full traceability, which greatly improves the reliability and efficiency of inspection.

[0102] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. An intelligent production line for ultra-long heavy-duty welded H-beams, characterized in that, Including those arranged sequentially along the material flow direction: Beveling equipment is used to bevele both ends of steel plates; Plate welding equipment is used to weld multiple steel plates into a large plate and to perform double-sided submerged arc welding on the weld seams; Slab cutting equipment is used to cut welded large plates into slabs of the required specifications and to perform beveling. Joint straightening equipment is used to correct deformation of the joints between slats; Grinding and chamfering equipment is used to grind and chamfer the cut surfaces and assembly surfaces of strips; H-beam assembly equipment is used to assemble the web and two flanges into H-beams using the "⊥-shaped → I-shaped" process. H-beam welding and forming equipment is used for automatic welding of assembled H-beams in ship-shaped and all-position positions. Flange straightening equipment is used for high-precision straightening of welded H-beam flanges; Weld inspection equipment is used for non-destructive testing and defect marking of the main welds of H-beams; And fixed-length cutting equipment, used for cutting finished H-beams to fixed lengths; The production line is managed by a Manufacturing Execution System (MES) with centralized monitoring and intelligent scheduling in the central control room; the equipment is connected to each other through an automated logistics system to achieve fully automated material flow.

2. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The panel welding equipment includes a hydraulic key-type clamping device, a dual-wire submerged arc welding system, a plasma gouging device, and a panel flipping mechanism. The hydraulic key-type clamping device is used to apply distributed pressure to both sides of the weld. The dual-wire submerged arc welding system is equipped with a laser vision sensor for weld trajectory tracking. The plasma gouging device is used to perform root cleaning on the back of the weld. The panel flipping mechanism is used to automatically flip large panels.

3. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The slab cutting equipment is a multi-head CNC flame cutting machine. The slab cutting equipment includes a linear cutting torch assembly, a beveling torch, and a CNC system. The linear cutting torch assembly is used to simultaneously cut multiple slabs; the beveling torch is used to complete beveling while cutting; and the CNC system is used to control the cutting path and beveling parameters.

4. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The seam straightening device includes a hydraulic straightener that moves up and down, and the hydraulic straightener uses a downward pressing method to straighten the seam.

5. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The H-beam assembly equipment includes a vertical assembly machine, a 90° web plate turning machine, and a 180° T-beam turning machine. The vertical assembly machine is used for precise alignment and assembly of the flange and web plate. The 90° web plate turning machine is used to turn the horizontally placed web plate into an upright position to complete the "⊥" welding of the flange and web plate. The 180° T-beam turning machine is used to turn the T-beam so that it can be assembled with another flange plate to form an "I" shape for welding.

6. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The H-beam welding and forming equipment includes multiple double-wire cantilever submerged arc welding machines, multiple 180° turning machines, multiple 55° welding frames, and a weld tracking system. The multiple double-wire cantilever submerged arc welding machines use welding wire for welding. The multiple 180° turning machines are used to turn the H-beam into its ship-shaped position. The multiple 55° welding frames are used to turn the H-beam into its ship-shaped welding state. The weld tracking system is used to automatically locate the weld start point and track the welding path.

7. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The wingplate straightening equipment includes a vertical straightening machine, a laser scanning measurement system, and a dynamic adjustment system. The vertical straightening machine is used to perform roller straightening on the upper and lower sides of the wingplate. The laser scanning measurement system is used to detect the deformation of the wingplate in real time. The dynamic adjustment system is used to dynamically adjust the straightening parameters according to the detection results. The straightening accuracy reaches ≤1mm in the wingplate width direction.

8. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The weld inspection equipment includes a phased array ultrasonic flaw detector, a data analysis system, and a defect marking device; the phased array ultrasonic flaw detector is used to inspect four main welds; the data analysis system is used to generate inspection reports and quality files based on the inspection results; and the defect marking device is used to accurately locate and mark non-conforming positions.

9. The intelligent production line for ultra-long heavy-duty welded H-beams according to claim 1, characterized in that, The automated logistics system includes conveyor rollers and truss-type KBK cranes. The total length of the conveyor rollers is greater than or equal to 500 meters, and the number of truss-type KBK cranes is at least 3 sets.

10. A method for producing ultra-long heavy-duty welded H-beams, implemented using the intelligent production line for ultra-long heavy-duty welded H-beams as described in any one of claims 1-9, characterized in that, Includes the following steps: The raw steel plates are beveled, assembled at the splicing station, and the front and back sides are welded and cleaned to obtain large plates. After the large plate is welded, it is cut into strips and beveled. Then the joints of the strips are straightened, and the cut surfaces and assembly surfaces of the strips are ground and chamfered. The processed slats are assembled into H-beams using the method of "first assembling the ⊥ type, then assembling the I type"; The assembled H-beams are then welded into a ship shape, and the flanges are straightened and the weld quality is inspected after welding. The qualified H-beams are cut to length to obtain finished H-beams; The method is managed by the Production Execution System (MES), monitored and scheduled by the central control room, and materials are automatically transferred between workstations through an automated logistics system.

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