A robust grid structure, welding process system and welding process

Abstract

The application discloses a stable grid structure, which comprises a plurality of equidistant parallel grid plates and a plurality of equidistant parallel grid bars, the plurality of grid plates and the plurality of grid bars are vertically staggered to form a grid-shaped stable grid body, the staggered positions of any grid plate and any grid bar are connected through welding, the upper side of the grid plate is provided with a plurality of bar clamping grooves arranged along the length direction, the grid bar is clamped in the bar clamping groove, and the lower end edge contour of the grid bar and the bar clamping groove is connected through welding, and a grid plate passageway is formed between any two adjacent grid plates, so that automatic dynamic sequential welding is realized, and the assembling and welding processes of the grid structure are simultaneously implemented.

Description

Technical Field

[0001] This invention belongs to the field of welding. Background Technology

[0002] In existing technologies, welding the manufacture of large mesh grid structures presents the following problems:

[0003] Welding after overall assembly: First, all grating plates and grating bars are manually positioned and assembled into a whole on large tooling. Then, workers use handheld welding torches or move welding machines via gantry cranes to weld hundreds or thousands of intersections one by one. This method has the problems of high labor intensity, low production efficiency, and high dependence on worker skills.

[0004] Low level of automation: Although some automated equipment exists, it is mostly limited to single actions (such as automatic wire feeding). There is a lack of effective integrated solutions for key process links such as the precise advancement of the grating, the synchronous conveying of the ribs, and how to efficiently achieve piece-by-piece welding without interfering with the already welded parts. Traditional methods often require moving the entire bulky grating body or complex tooling when welding a single grating, which is inefficient. Summary of the Invention

[0005] Purpose of the invention: In order to overcome the shortcomings of the existing technology, the present invention provides a stable grid structure, welding process system and welding process, realizing an automated dynamic sequential welding system that synchronizes the assembly and welding process of the grid structure, and realizing the leap from "piece-by-piece welding" to "assembly line" welding.

[0006] Technical Solution: To achieve the above objectives, the present invention provides a stable grid structure comprising several equidistant parallel grid plates and several equidistant parallel grid ribs, wherein the grid plates and grid ribs are perpendicularly intersected to form a grid-like stable grid body; the intersections of any grid plate and any grid rib are connected by welding; several rib slots are arrayed along the length direction on the upper side of the grid plate; the grid ribs are engaged in the rib slots, and the lower edge contours of the grid ribs and the rib slots are connected by welding; a grid plate passage is formed between any two adjacent grid plates.

[0007] Furthermore, the lower end of each rib groove has a rounded outline; each grating rib is a straight steel pipe, and the grating plate is a long, flat steel plate.

[0008] Furthermore, the system includes a horizontal transmission platform. On the transmission surface of the horizontal transmission platform, a horizontally overlapping body of grid plates, composed of several parallel, adjacent, and laterally aligned grid plates, is supported. The vertical direction of the face of each grid plate on the horizontally overlapping body is parallel to the transmission direction of the transmission surface. The rib slots of any two adjacent grid plates in the horizontally overlapping body are aligned with each other, and the aligned and connected rib slots together form a shuttle channel parallel to the transmission direction of the transmission surface. The system also includes several grid ribs parallel to the transmission direction of the transmission surface, a guide device that constrains each grid rib, allowing the grid ribs to move only along their own length under the constraint of the guide device, and a drive device that can drive the grid ribs to move along their own length under the constraint of the guide device. Each grid rib shuttles along its length through its corresponding shuttle channel. A horizontal guide rail is provided at the front of the transmission end of the horizontal transmission platform, with the extension direction of the horizontal guide rail perpendicular to the transmission direction of the horizontal transmission platform. A displacement slider is provided on the horizontal guide rail, and a welding machine is fixedly mounted on the displacement slider.

[0009] Furthermore, in the transverse overlapping body of the grating plates, the first grating plate counting from front to back is grating plate a, and the second grating plate is grating plate b; in the initial state, grating plate a is exactly at the end of the conveying surface.

[0010] Furthermore, as the displacement slider moves along the horizontal guide rail, the end of the welding torch successively corresponds to the lower edge contour of each rib groove on the grating plate.

[0011] Furthermore, a clamping roller is arranged parallel to the upper end of the grating plate a, and the rotating shafts at both ends of the clamping roller are rotatably mounted on the roller bracket through bearings; it also includes a roller drive device that can drive the clamping roller to rotate actively; the outer contour of the clamping roller in the axial view is a cam contour that gradually approaches the axis in the clockwise direction; in the initial state, the lower end of the outer peripheral surface of the clamping roller is tightly tangent to the upper surface of the grating plate a, and when the clamping roller rotates counterclockwise around the axis by a certain angle, the lower end of the outer peripheral surface of the clamping roller separates from the upper surface of the grating plate a.

[0012] Furthermore, a welding process for a robust grid structure welding system:

[0013] Step 1: In the initial state, grating plate a is at the end of the conveyor surface; control the displacement slider to move along the horizontal guide rail, so that the end of the welding gun will weld the lower edge contour of each rib groove of grating plate a one by one, thereby welding grating plate a to several grating ribs.

[0014] Step 2: Control the clamping roller to rotate counterclockwise around the axis by a certain angle, so that the lower end of the outer circumference of the clamping roller separates from the upper end of the grating plate a, and the clamping roller releases the downward pressure on the grating plate a; at the same time, control the displacement slider to move until the welding machine deviates from the front of the grating plate a.

[0015] Step 3: Control the conveying surface of the horizontal conveying platform to move forward at a speed of V. At the same time, the drive device synchronously drives several grid ribs to move forward at a speed of V along their own length direction under the constraint of the guide device. This causes the horizontally overlapping grid plates to shift forward as a whole at a speed of V under the synchronous forward action of the conveying surface and the grid ribs, until the lower end of the frontmost grid plate a in the horizontally overlapping grid plates moves forward to the end of the conveying surface, while grid plate b reaches the position of grid plate a in "Step 1". Then, immediately stop the movement of the conveying surface and the grid ribs. At this time, the lower end of grid plate a is detached from the support of the conveying surface, and the upper end of grid plate a is "suspended" on the grid ribs by welding.

[0016] Step 4: Control the clamping roller to rotate clockwise around the axis by a certain angle, so that the lower end of the outer circumference of the clamping roller presses tightly against the upper end of the b grid plate, so that the b grid plate is tightly clamped between the clamping roller and the conveying surface at the end of the horizontal conveying platform.

[0017] Step 5: Keep the conveying surface of the horizontal conveying platform stationary, and then drive the drive device to synchronously drive several grid ribs to move forward at a speed of V along their own length direction under the constraint of the guide device; so that each grid rib moves forward along its corresponding shuttle channel, and the grid plate a "suspended" on several grid ribs moves forward at a speed of V, while the other grid plates that overlap laterally remain stationary; until a grid plate passage of a predetermined width is formed between grid plate a and grid plate b.

[0018] Step six: Control the displacement slider to move along the horizontal guide rail in the newly formed grating plate passage, so that the end of the welding gun will weld the lower edge contour of each rib groove of the b grating plate in turn, thereby welding the b grating plate and several grating ribs together; at this time, the "b grating plate" will be transformed into the "a grating plate" at the end of "step one".

[0019] Step 7: Repeat the process from Step 2 to Step 6 continuously, so that a predetermined number of grid plates on the transverse overlapping body of the grid plates are welded to several grid ribs in an equidistant distribution from front to back, forming a grid-like stable grid body.

[0020] Beneficial Effects: The core innovation of this invention lies in proposing an automated, dynamic sequential welding system and process. This system breaks down the assembly and welding process of the grid structure into a series of precisely controlled steps, achieving a leap from "piece-by-piece welding" to "assembly line" welding. Specific innovations are as follows:

[0021] The pre-fabricated rib slots with rounded lower ends on the grating plate provide a natural placement position for the grating ribs, ensuring that all intersections are automatically aligned; at the same time, it provides a basis for the grating ribs to act as "guide rails" and "transmission mediums".

[0022] This solution pre-aligns and overlaps multiple grating panels, allowing their rib slots to form a continuous "shuttle channel." This design enables multiple grating ribs to pass through all the grating panels at once, like threading a needle, achieving batch pre-assembly and laying a solid foundation for subsequent piece-by-piece welding.

[0023] In step three, the horizontal transport platform and all the grid ribs are controlled to move synchronously at the same speed V1. This mechanism ensures that the entire overlapping grid panel moves smoothly as a whole until the first grid panel (grid panel a) detaches from the platform support without relative sliding or jamming on the ribs, achieving precise station transition.

[0024] Technological innovation:

[0025] "Suspended welding" and dynamic separation process: This is the core technological innovation of this solution. First, the first grating plate (grating plate a) is welded to the ribs, making it "suspended" on the ribs. Then, in step five, by driving the ribs forward at speed V2 alone, the welded grating plate a is pulled forward, separating it from the subsequent overlapping grating plates, automatically forming a "grating passage" for the welding torch to enter. This method cleverly utilizes the welded portion as a traction point, achieving non-interference dynamic spacing generation without moving heavy tooling or the entire grating body.

[0026] The clamping rollers are designed with a cam-like outer contour, allowing for quick and reliable switching between "clamping" and "releasing" states through simple rotation. During welding (steps one and six), the clamping rollers clamp the current grating plate to prevent movement. During overall conveying (step two), the welded plates are released to avoid interference. During separation to form a passageway (step four), the next grating plate to be welded (grating plate b) is clamped, effectively resisting the friction generated when the ribs pass through, preventing tilting or displacement, and ensuring the stability and precision of the process.

[0027] Dual-speed control strategy (V1 & V2): The system employs two different transmission speeds: V1 for smooth overall transport, and V2 for rapid separation to form aisles. This differentiated speed control optimizes production cycle time, improving overall efficiency while ensuring accuracy and stability.

[0028] A recyclable automated process: The entire "welding-release-transfer-separation-re-welding" process is designed as a closed-loop process that can be repeated indefinitely until all grating plates are welded. This design enables large-scale, continuous production, greatly improving production efficiency and ensuring consistency and high quality in product spacing. Attached Figure Description

[0029] Figure 1 A schematic diagram of a grid-like stable grid structure;

[0030] Figure 2 This is a schematic diagram of the grating structure;

[0031] Figure 3 This is a schematic diagram for "Step One" of this plan;

[0032] Figure 4 for Figure 3 Side view in the current state;

[0033] Figure 5 This is a diagram showing the end of "Step Five";

[0034] Figure 6 This is a diagram showing the end of "Step Seven". Detailed Implementation

[0035] The invention will now be further described with reference to the accompanying drawings.

[0036] As attached Figures 1 to 6 As shown; the welding object of this scheme is a stable grid structure, such as... Figure 1 and 2 As shown, the structure includes several equidistant parallel grating plates 1 and several equidistant parallel grating ribs 2. The grating plates 1 and grating ribs 2 are perpendicularly intersected to form a stable grid body 13. At any intersection of the grid plate 1 and any grating rib 2 on this stable grid body 13, they are connected by welding. Several rib slots 3 are arranged in an array along the length direction on the upper side of each grating plate 1, and the lower end of each rib slot 3 has a rounded contour. The grating ribs 2 are inserted into the rib slots 3, and the lower edge contours of the grating ribs 2 and the rib slots 3 are connected by welding. A grating passageway 14 is formed between any two adjacent grating plates 1. Each grating rib 2 is a straight steel pipe, and the grating plate 1 is a long, flat steel plate. This structural design, through the perpendicular intersecting welding of the grating plates and grating ribs, forms a high-strength grid-like support system. The rounded contour design of the rib slots not only facilitates the insertion of the grating ribs but also provides a larger contact area for welding, thereby enhancing the strength and stability of the weld points.

[0037] This solution provides a welding system for a robust grid structure, the structural components of which are as follows: Figure 3 and 4As shown, the system includes a horizontal transmission platform 11. A transverse overlapping body 20 of grid plates 1, formed by parallel, adjacent, and laterally aligned grid plates 1, is supported on the transmission surface 12 of the horizontal transmission platform 11. The vertical direction of the surface of each grid plate 1 on the transverse overlapping body 20 is parallel to the transmission direction of the transmission surface 12. The rib slots 3 of any two adjacent grid plates 1 in the transverse overlapping body 20 are aligned with each other, and the aligned and connected rib slots 3 together form a shuttle channel 21 parallel to the transmission direction of the transmission surface 12. The guiding device can be a ball bearing guide sleeve; the driving device can be a servo motor or a hydraulic cylinder to provide precise speed control.

[0038] It also includes several grid ribs 2 parallel to the transmission direction of the conveying surface 12, and a guide device for constraining each grid rib 2. Under the constraint of the guide device, the grid rib 2 can only move along its own length direction. It also includes a drive device that can drive the grid rib 2 to move along its own length direction under the constraint of the guide device. Each grid rib 2 shuttles through the corresponding shuttle channel 21 along its length direction. The first grid plate 1 from front to back in the grid plate transverse overlapping body 20 is denoted as grid plate a 1a, and the second grid plate 1 is denoted as grid plate b 1b. In the initial state, grid plate a 1a is just at the end of the transmission of the conveying surface 12.

[0039] A horizontal guide rail 10 is provided on the front side of the conveying end of the horizontal conveying platform 11. The extension direction of the horizontal guide rail 10 is perpendicular to the conveying direction of the horizontal conveying platform 11. A displacement slider 9 is provided on the horizontal guide rail 10. The welding machine 8 is fixedly installed on the displacement slider 9. The welding gun 7 of the welding machine 8 is set at an angle upward. During the displacement of the displacement slider 9 along the horizontal guide rail 10, the end of the welding gun 7 corresponds to the lower edge contour of each rib groove 3 on the a-grid plate 1a.

[0040] A clamping roller 6 is arranged parallel to the upper end of the grating plate 1a. The rotating shafts at both ends of the clamping roller 6 are rotatably mounted on the roller bracket 4 through bearings. It also includes a roller drive device that can drive the clamping roller 6 to rotate actively. The outer contour of the clamping roller 6 in the axial view is a cam contour that gradually approaches the axis in the clockwise direction. In the initial state, the lower end of the outer peripheral surface of the clamping roller 6 is tightly tangent to the upper end surface of the grating plate 1a. When the clamping roller 6 rotates counterclockwise around the axis by a certain angle, the lower end of the outer peripheral surface of the clamping roller 6 separates from the upper end surface of the grating plate 1a.

[0041] Specific welding process:

[0042] Step 1: In the initial state, the grating plate 1a is just at the end of the conveying surface 12; control the displacement slider 9 to move along the horizontal guide rail 10, so that the end of the welding gun 7 will weld the lower edge contour of each rib groove 3 of the grating plate 1a in turn, thereby welding the grating plate 1a and several grating ribs 2 together.

[0043] Step 2: Control the clamping roller 6 to rotate counterclockwise around the axis by a certain angle, so that the lower end of the outer peripheral surface of the clamping roller 6 separates from the upper end surface of the grid plate 1a, and the clamping roller 6 releases the downward pressure on the grid plate 1a; at the same time, control the displacement slider 9 to move until the welding machine 8 deviates from the front of the grid plate 1a, so as to avoid motion interference in subsequent steps.

[0044] Step 3: Control the conveying surface 12 of the horizontal conveying platform 11 to convey forward at a speed of V1. At the same time, the driving device synchronously drives several grid ribs 2 to move forward at a speed of V1 along their own length direction under the constraint of the guiding device. This causes the transverse overlapping body 20 of the grid plate to shift forward as a whole at a speed of V1 under the synchronous forward action of the conveying surface 12 and several grid ribs 2, until the lower end of the frontmost grid plate 1a of the transverse overlapping body 20 moves forward to just detach from the conveying end of the conveying surface 12, while the grid plate 1b just reaches the position of the grid plate 1a at the time of "Step 1". Then, immediately stop the movement of the conveying surface 12 and several grid ribs 2.

[0045] At this time, the lower end of the grating plate 1a is detached from the support of the conveying surface 12, and the upper end of the grating plate 1a is "suspended" on several grating ribs 2 by welding.

[0046] Step 4: Control the clamping roller 6 to rotate clockwise around the axis by a certain angle, so that the lower end of the outer peripheral surface of the clamping roller 6 presses tightly against the upper end surface of the b grid plate 1b, so that the b grid plate 1b is tightly clamped between the clamping roller 6 and the conveying surface 12 at the end of the conveying of the horizontal conveying platform 11; effectively avoiding the problem of the b grid plate 1b tilting and shifting during the next step.

[0047] Step 5: Keep the conveying surface 12 of the horizontal conveying platform 11 stationary, and then the driving device synchronously drives several grid ribs 2 to move forward at a speed of V2 along their own length direction under the constraint of the guiding device; thus, each grid rib 2 shuttles forward along its corresponding shuttle channel 21, and the grid plate 1a "suspended" on the several grid ribs 2 moves forward at a speed of V2, while the other grid plate transverse overlaps 20 remain stationary; until a grid plate passage 14 of predetermined width is formed between grid plate 1a and grid plate 1b; as Figure 5 As shown. The speed V2 is usually greater than V1 to quickly form the grating passage 14 and improve production efficiency; the predetermined width is set according to design requirements and is usually controlled by an encoder or position sensor.

[0048] Step six: Control the displacement slider 9 to move along the horizontal guide rail 10 through the newly formed grating plate passage 14, so that the end of the welding gun 7 successively welds the lower edge contour of each rib groove 3 of the b grating plate 1b, thereby welding the b grating plate 1b to several grating ribs 2 and making them a whole; thus, the process of welding the a grating plate 1a and the b grating plate 1b onto several grating ribs 2 is realized; at this time, the "b grating plate 1b" is transformed into the "a grating plate 1a" at the end of "step one";

[0049] Step seven, continuously repeating the process from "Step two" to "Step six", so that a predetermined number of grid plates 1 on the transverse overlapping body 20 are welded to several grid ribs 2 in a sequentially equidistant distribution from front to back, forming a mesh-like stable grid body 13, as shown. Figure 6 As shown; finally, the remaining grid ribs 2 at the rear end of the newly formed grid-shaped stable grid body 13 can be cut off using a cutting device.

[0050] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A welding system for a stable grid structure, the stable grid structure comprising a plurality of equidistant parallel grid plates (1) and a plurality of equidistant parallel grid ribs (2), the plurality of grid plates (1) and the plurality of grid ribs (2) being perpendicularly intersected to form a grid-like stable grid body (13); the intersection of any grid plate (1) and any grid rib (2) is connected by welding. The upper side of the grating plate (1) is provided with a number of rib slots (3) arranged in an array along the length direction; the grating ribs (2) are inserted into the rib slots (3), and the lower edge contours of the grating ribs (2) and the rib slots (3) are connected by welding; a grating plate passage (14) is formed between any two adjacent grating plates (1). Its features are: The welding system includes a horizontal transfer platform (11), on which a horizontally overlapping grid plate body (20) is supported, which is composed of several grid plates (1) that are parallel to each other and horizontally aligned and overlapped. The vertical direction of the surface of each grid plate (1) on the horizontally overlapping grid plate body (20) is parallel to the transfer direction of the transfer surface (12). The rib slots (3) of any two adjacent grid plates (1) of the horizontally overlapping grid plate body (20) are aligned with each other, and the several aligned and connected rib slots (3) are combined to form a shuttle channel (21) parallel to the transfer direction of the transfer surface (12). It also includes several rib slots that are parallel to the transfer direction of the transfer surface (12). The grid ribs (2) are arranged in rows, and a guide device is also included to constrain each grid rib (2). Under the constraint of the guide device, the grid ribs (2) can only move along their own length direction. The guide device is also included to drive the grid ribs (2) to move along their own length direction under the constraint of the guide device. Each grid rib (2) shuttles through the corresponding shuttle channel (21) along its length direction. A horizontal guide rail (10) is provided on the front side of the conveying end of the horizontal conveying platform (11). The extension direction of the horizontal guide rail (10) is perpendicular to the conveying direction of the horizontal conveying platform (11). A displacement slider (9) is provided on the horizontal guide rail (10), and the welding machine (8) is fixedly installed on the displacement slider (9). In the transverse overlapping body of the grid plates (20), the first grid plate (1) counting from front to back is grid plate a (1a), and the second grid plate (1) is grid plate b (1b); in the initial state, grid plate a (1a) is just at the end of the conveying surface (12); During the displacement of the slider (9) along the horizontal guide rail (10), the end of the welding gun (7) corresponds to the lower edge contour of each rib groove (3) on the grid plate (1a) in turn. A clamping roller (6) is arranged parallel to the upper end of the grating plate (1a). The rotating shafts at both ends of the clamping roller (6) are rotatably mounted on the roller bracket (4) through bearings. It also includes a roller drive device that can drive the clamping roller (6) to rotate actively. The outer contour of the clamping roller (6) in the axial view is a cam contour that gradually approaches the axis in the clockwise direction. In the initial state, the lower end of the outer peripheral surface of the clamping roller (6) is tightly tangent to the upper end surface of the grating plate (1a). When the clamping roller (6) rotates counterclockwise around the axis by a certain angle, the lower end of the outer peripheral surface of the clamping roller (6) separates from the upper end surface of the grating plate (1a).

2. The welding system for a stable grid structure according to claim 1, characterized in that: The lower end of each of the rib slots (3) has a rounded profile; each grid rib (2) is a straight steel pipe, and the grid plate (1) is a long flat steel plate.

3. The welding process of the welding system for a stable grid structure according to claim 2, characterized in that: Step 1: In the initial state, the a grid plate (1a) is at the end of the conveying surface (12); control the displacement slider (9) to move along the horizontal guide rail (10) so that the end of the welding gun (7) welds the lower edge contour of each rib groove (3) of the a grid plate (1a) in turn, thereby welding the a grid plate (1a) to several grid ribs (2). Step 2: Control the clamping roller (6) to rotate counterclockwise around the axis by a certain angle, so that the lower end of the outer peripheral surface of the clamping roller (6) is separated from the upper end surface of the grid plate (1a), and the clamping roller (6) releases the downward pressure on the grid plate (1a); at the same time, control the displacement slider (9) to move until the welding machine (8) deviates from the front of the grid plate (1a); Step 3: Control the conveying surface (12) of the horizontal conveying platform (11) to move forward at a speed of V1. At the same time, the driving device synchronously drives several grid ribs (2) to move forward at a speed of V1 along their own length direction under the constraint of the guiding device. Then, the horizontal overlapping body (20) of the grid plate is shifted forward as a whole under the synchronous forward action of the conveying surface (12) and several grid ribs (2) until the lower end of the frontmost grid plate (1a) of the horizontal overlapping body (20) moves forward to just detach from the conveying end of the conveying surface (12), and the grid plate (1b) just reaches the position of the grid plate (1a) at the time of "Step 1". Then immediately stop the movement of the conveying surface (12) and several grid ribs (2). At this time, the lower end of the grid plate (1a) is detached from the support of the conveying surface (12), and the upper end of the grid plate (1a) is "suspended" on several grid ribs (2) by welding. Step 4: Control the clamping roller (6) to rotate clockwise around the axis by a certain angle, so that the lower end of the outer peripheral surface of the clamping roller (6) presses tightly against the upper end surface of the b grid plate (1b), so that the b grid plate (1b) is tightly clamped between the clamping roller (6) and the conveying surface (12) at the end of the conveying of the horizontal conveying platform (11). Step 5: Keep the conveying surface (12) of the horizontal conveying platform (11) stationary, and then drive the drive device to drive several grid ribs (2) to move forward at a speed of V2 along their own length direction under the constraint of the guide device; thereby causing each grid rib (2) to shuttle forward along the corresponding shuttle channel (21), and the grid plate (1a) "suspended" on several grid ribs (2) moves forward at a speed of V2, while the other grid plate transverse overlaps (20) remain stationary; until a grid plate passage (14) of a predetermined width is formed between the grid plate (1a) and the grid plate (1b). Step six, control the displacement slider (9) to move along the horizontal guide rail (10) in the newly formed grating plate passage (14), so that the end of the welding gun (7) successively welds the lower edge contour of each rib slot (3) of the b grating plate (1b), thereby welding the b grating plate (1b) and several grating ribs (2) together; at this time, the "b grating plate (1b)" is transformed into the "a grating plate (1a)" at the end of "step one"; Step 7: Repeat the process from "Step 2" to "Step 6" to weld a predetermined number of grid plates (1) on the transverse overlapping body (20) to several grid ribs (2) in an equidistant distribution from front to back, forming a grid-like stable grid body (13).

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