Arc-shaped reinforcing mesh multi-welding-spot welding device and method

Abstract

The invention relates to the technical field of reinforcing mesh welding, and discloses a multi-welding-spot welding device and method for an arc-shaped reinforcing mesh. The technical problems that in the prior art, positioning is difficult, efficiency is low, precision is poor, and adaptability is weak in the welding process of the cambered surface reinforcing mesh are solved. The device comprises a walking mechanism; the bottom of a mechanism frame is connected to the walking mechanism, an arc-surface steel bar beam is fixedly installed on the top of the mechanism frame, and an arc-surface welding mechanism is slidably installed on the arc-surface steel bar beam. The cambered surface welding mechanism is connected with one end of the welding mechanism telescopic structure, and the other end of the welding mechanism telescopic structure is connected with the welding clamping mechanism. The equipment can accurately move along a cambered surface track, automatically adjust the welding position and parameters, ensure the stable quality of welding spots, meet the welding requirements of cambered surface reinforcing meshes with different specifications, realize automatic welding of a plurality of arc-shaped reinforcing steel bars and improve the cage forming speed of the arc-shaped reinforcing steel meshes.

Description

Technical Field

[0001] This invention relates to the field of steel mesh welding technology, and in particular to a multi-point welding device and method for arc-shaped steel mesh. Background Technology

[0002] During tunnel construction, the tunnel cross-section exhibits an arc-shaped structure. To meet the welding requirements of the reinforcing bars on this arc-shaped interface, resistance spot welding has become one of the mainstream technologies in the manufacturing of reinforcing mesh due to its reliable connection and high efficiency. For welding planar reinforcing mesh, mature automated welding equipment already exists, capable of automatically positioning and synchronously welding multiple intersection points of the mesh through a matrix arrangement of welding torches. However, when dealing with arc-shaped reinforcing mesh with a specific radius of curvature, the production process becomes more complex. To ensure the geometric accuracy and structural performance of the arc-shaped mesh, it is necessary to ensure that all longitudinal and transverse reinforcing bars maintain a preset relative position in three-dimensional space during the forming process, and to achieve reliable connections at numerous intersection points. This involves a series of technical aspects, including the bending and shaping of the reinforcing bars, precise positioning in welding fixtures, and energy control of multiple welding points. Existing technologies include various specialized molds and fixing devices for processing arc-shaped components. Meanwhile, in the welding field, multi-head welding systems and programmable welding control technology are well-known in the industry. These technologies provide the necessary technical foundation and practical experience for the industrial production of arc-shaped reinforcing mesh.

[0003] Chinese patent document 202420558715.8 discloses a rebar welding robot, comprising: a base, with two support seats slidably connected to the top surface of the base, and a clamping assembly for clamping the rebar. An electric hydraulic rod drives a first mounting shell to move downward, and then the first mounting shell drives multiple connecting discs and multiple pressure blocks inside it to move downward. When the upper rebar enters between the two pressure blocks, the two pressure blocks will move away from each other under the downward pressure of the electric hydraulic rod, and then the pressure blocks will squeeze multiple first springs. Then the rebound force of the first springs will push the two pressure blocks to fit against the surface of the rebar, thereby positioning the upper rebar. Then, a welding robotic arm is used to weld the upper and lower rebars. The spacing between the two pressure blocks can be adjusted.

[0004] However, the above-mentioned solutions suffer from at least the following technical problems during implementation: difficulty in positioning, low efficiency, poor accuracy, and weak adaptability during the welding of curved steel mesh. Therefore, there is an urgent need to propose a multi-point welding device and method for curved steel mesh. Summary of the Invention

[0005] In view of the above technical problems, this disclosure provides a multi-point welding device and method for arc-shaped steel mesh, which solves the technical problems of difficult positioning, low efficiency, poor accuracy, and weak adaptability in the welding process of arc-shaped steel mesh in the prior art. The device should be able to move accurately along the arc trajectory, automatically adjust the welding position and parameters to ensure stable weld quality, and adapt to the welding needs of arc-shaped steel mesh of different specifications. It can realize the automatic welding of multiple arc-shaped steel bars and improve the cage formation speed of arc-shaped steel mesh.

[0006] According to one aspect of this disclosure, a multi-point welding device for arc-shaped steel mesh is provided, comprising a traveling mechanism for moving the entire device along a straight trajectory to adjust the relative position of the device and the arc-shaped steel mesh to be welded; the bottom of a mechanism frame is connected to the traveling mechanism to support the main structure of the device; an arc-shaped steel beam is fixedly installed on the top of the mechanism frame, the curvature of which is adapted to the curvature of the arc-shaped steel mesh to be welded; an arc-shaped welding mechanism is slidably installed on the arc-shaped track beam and moves back and forth along the arc-shaped trajectory of the arc-shaped track beam to achieve welding coverage of different arc-shaped positions of the arc-shaped steel mesh; one end of the arc-shaped welding mechanism is connected to a welding mechanism telescopic structure, and the other end of the welding mechanism telescopic structure is connected to a welding clamping mechanism; the welding mechanism telescopic structure extends and retracts in a direction perpendicular to the arc-shaped track beam to adjust the distance between the welding clamping mechanism and the steel bar to be welded; the welding clamping mechanism is used to clamp and fix the steel bar to be welded.

[0007] In some embodiments of this disclosure, the welding clamping mechanism includes an adjustable clamping end, the size of which is adapted to the diameter of the reinforcing bar to be welded, so as to stabilize the position of the reinforcing bar during the welding process.

[0008] In some embodiments of this disclosure, welding positive and welding negative electrodes are respectively installed on both sides of the welding clamping mechanism to provide pressure and circuit channels during the clamping process, and welding is achieved through current heating and pressure.

[0009] In some embodiments of this disclosure, the walking mechanism, the arc welding mechanism, the welding mechanism telescopic structure, the welding clamping mechanism, the welding positive electrode, and the welding negative electrode are electrically connected to the welding machine control module for controlling the coordinated operation of each mechanism. This includes controlling the start and stop and the moving speed of the walking mechanism, controlling the moving trajectory and speed of the arc welding mechanism along the arc track beam, controlling the extension and retraction of the welding mechanism telescopic structure to adjust the welding position, controlling the clamping and releasing actions of the welding clamping mechanism, and controlling the energizing time, current magnitude, and welding parameters of the welding positive and welding negative electrodes.

[0010] In some embodiments of this disclosure, the walking mechanism includes a drive motor, the power output end of which is connected to a transmission gear. The transmission gear meshes with one side of a rack, and the drive motor drives the walking mechanism to move along a ground guide rail through the transmission gear. A guide wheel is installed on the other side of the rack to ensure the straightness of the walking trajectory.

[0011] In some embodiments of this disclosure, a position sensor is provided on the arc-shaped track beam to detect the position information of the arc-shaped welding mechanism in real time, so as to feed the position information back to the welding machine control module and realize the control of the welding position.

[0012] In some embodiments of this disclosure, the telescopic structure of the welding mechanism is an electric push rod or a hydraulic cylinder, and the telescopic range of the electric push rod or hydraulic cylinder is controlled by the welding machine control module.

[0013] In some embodiments of this disclosure, the welding clamping mechanism includes grippers, and the opening and closing control end of the grippers is equipped with a drive cylinder for adjusting the distance between the grippers to accommodate steel bars with a diameter of 6~32mm to be welded.

[0014] In some embodiments of this disclosure, the welding machine control module includes a PLC controller. The display output terminal of the PLC controller is equipped with a touch screen for parameter setting and operation status display. The sensing signal input terminal of the PLC controller is connected to a sensor module. The sensor module includes a vision sensor for detecting the position of the rebar to be welded and an infrared sensor for detecting the temperature of the weld point.

[0015] A method for welding multiple weld points of an arc-shaped steel mesh, applicable to multiple weld point welding devices for arc-shaped steel mesh, includes the following steps: (1) Parameter setting: The welding path, welding speed, welding current, power-on time and action parameters of each mechanism are set through the touch screen of the welding machine control module; (2) Overall positioning of the device: Start the walking mechanism, and the drive motor drives the entire device to move along the ground guide rail through the meshing of the transmission gear and the ground rack until it reaches the starting position of the target welding area; during this process, the guide wheel ensures the straightness of the movement trajectory; (3) Arc welding point positioning: control the arc welding mechanism to move along the arc track beam, and use the real-time position information fed back by the position sensor to accurately position the welding unit to the arc coordinates where the target welding point is located; (4) Approaching the welding point: Control the telescopic structure of the welding mechanism to push the welding clamping mechanism to extend towards the steel bar to be welded and adjust to a suitable welding distance; (5) Clamping and energizing: The drive cylinder of the welding clamping mechanism is controlled to drive the jaws to close and firmly clamp the steel bar to be welded, so that the welding positive and welding negative electrodes are in close contact with the surface of the steel bar; then, the welding machine control module connects the circuit according to the set parameters to perform energized welding. (6) Complete single-point welding: After the set welding time is reached, the welding machine control module cuts off the welding current, then controls the drive cylinder to release the gripper and retract the welding mechanism telescopic structure to disengage from the weld point; (7) Cyclic welding: Repeat steps (3) to (6) to drive the arc welding mechanism to move along the arc track beam and complete the welding operation of all preset arc welding points at the current straight position point by point; (8) Move to the next station: Control the walking mechanism to move the device to the next straight station and repeat steps (2) to (7) until all welding points on the entire arc-shaped steel mesh are completed.

[0016] The beneficial effects of this invention are as follows: It achieves high-precision spatial positioning and adaptive welding. Through a three-dimensional collaborative motion mechanism of linear positioning of the walking mechanism, arc positioning of the arc welding mechanism, and radial fine adjustment of the telescopic device, combined with position sensor feedback, it realizes the accurate and rapid positioning of the welding unit in the arc-shaped steel mesh space. It can adapt to complex arc geometry and effectively ensure the positional accuracy of each weld point.

[0017] The device improves welding efficiency and automation by integrating a single automated process of walking, positioning, clamping, and welding. Centralized control via a PLC welding machine control module enables fully automated operation from single-point positioning to completing the welding of the entire rebar mesh. This significantly reduces manual intervention, avoids the waiting time associated with frequent adjustments to hoisting and welding equipment in traditional methods, and substantially improves production efficiency.

[0018] It ensures the uniformity and reliability of welding quality. The adjustable clamping end and the dedicated welding positive and negative electrode design ensure stable clamping of the steel bar to be welded and good circuit connection during the welding process, avoiding incomplete welding and false welding.

[0019] The PLC controller can precisely control core parameters such as welding current and energizing time, and can perform real-time monitoring and closed-loop control through vision sensors and infrared sensors to ensure consistent and reliable quality of each weld point and reduce quality fluctuations caused by human factors.

[0020] With its excellent versatility and flexibility, wide compatibility with reinforcing bars, and the drive cylinder and adjustable jaw design of the clamping mechanism, it can stably clamp various specifications of reinforcing bars with diameters ranging from 6mm to 32mm, making it suitable for a wide range of applications.

[0021] It can adapt to different curvatures, and the curved track beam can be customized and replaced according to the curvature of the steel mesh in the actual project, so that the device can be flexibly applied to a variety of curved structure projects with different curvature radii.

[0022] Stable operation and convenient use are ensured by the rack and pinion drive and guide wheels in the walking mechanism, which features smooth and precise linear movement of the entire machine. The touchscreen makes parameter settings intuitive and status monitoring clear, reducing the technical threshold and workload for operators. Attached Figure Description

[0023] Figure 1 A schematic diagram of a multi-welding-point welding device for arc-shaped steel mesh; Figure 2 for Figure 1 Enlarged view of the structure of section A in the middle; Figure 3 Schematic diagram of the walking mechanism of a multi-welding-point welding device for arc-shaped steel mesh; Figure 4 A partial enlarged view of the walking mechanism of the multi-welding-point welding device for arc-shaped steel mesh; Figure 5 This is a block diagram of the welding machine control module. The components in the diagram are named as follows: 1. Walking mechanism; 2. Curved steel mesh to be welded; 3. Mechanism frame; 4. Curved steel beam; 5. Curved welding mechanism; 6. Telescopic structure of welding mechanism; 7. Welding clamping mechanism; 8. Welding positive electrode; 9. Welding negative electrode; 10. Drive motor; 11. Transmission gear; 12. Rack; 13. Guide wheel; 14. Gripper. Detailed Implementation

[0024] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example 1

[0025] This example discloses a multi-point welding device and method for arc-shaped steel mesh. (See also...) Figures 1 to 5The device includes a walking mechanism 1, which moves the entire device along a straight track to adjust the relative position of the device and the arc-shaped steel mesh 2 to be welded. The bottom of the mechanism frame 3 is connected to the walking mechanism 1 to support the main structure of the device. The top of the mechanism frame 3 is fixedly installed with an arc-shaped steel beam 4, the curvature of which matches the curvature of the arc-shaped steel mesh 2 to be welded. An arc-shaped welding mechanism 5 is slidably installed on the arc-shaped track beam 4 and moves back and forth along the arc-shaped track beam 4 to achieve welding coverage of different arc-shaped positions of the arc-shaped steel mesh. The arc-shaped welding mechanism 5 is connected to one end of the welding mechanism telescopic structure 6, and the other end of the welding mechanism telescopic structure 6 is connected to the welding clamping mechanism 7. The welding mechanism telescopic structure 6 extends and retracts in a direction perpendicular to the arc-shaped track beam 4 to adjust the distance between the welding clamping mechanism 7 and the steel bar to be welded. The welding clamping mechanism 7 is used to clamp and fix the steel bar to be welded.

[0026] The welding clamping mechanism 7 includes an adjustable clamping end, the size of which is adapted to the diameter of the reinforcing bar to be welded, so as to stabilize the position of the reinforcing bar during the welding process. Welding positive electrode 8 and welding negative electrode 9 are respectively installed on both sides of the welding clamping mechanism 7 to provide pressure and circuit channels during the clamping process, and welding is achieved by heating with current and pressure.

[0027] The traveling mechanism 1, the arc welding mechanism 5, the welding mechanism telescopic structure 6, the welding clamping mechanism 7, the welding positive electrode 8, and the welding negative electrode 9 are electrically connected to the welding machine control module. This module is used to control the coordinated actions of each mechanism, including controlling the start, stop, and movement speed of the traveling mechanism 1; controlling the movement trajectory and speed of the arc welding mechanism 5 along the arc track beam 4; controlling the extension and retraction of the welding mechanism telescopic structure 6 to adjust the welding position; controlling the clamping and releasing actions of the welding clamping mechanism 7; and controlling the energizing time, current magnitude, and welding parameters of the welding positive and welding negative electrodes.

[0028] The walking mechanism 1 includes a drive motor 10. The power output end of the drive motor 10 is connected to a transmission gear 11. The transmission gear 11 meshes with one side of the rack 12. The drive motor 10 drives the walking mechanism 1 to move along the ground guide rail through the transmission gear 11. A guide wheel 13 is installed on the other side of the rack 12 to ensure the straightness of the walking trajectory.

[0029] A position sensor is installed on the curved track beam 4 to detect the position information of the curved welding mechanism 5 in real time, so as to feed the position information back to the welding machine control module and realize the control of the welding position.

[0030] The telescopic structure 6 of the welding mechanism is an electric push rod or a hydraulic cylinder, and the telescopic range of the electric push rod or hydraulic cylinder is controlled by the welding machine control module.

[0031] The welding clamping mechanism 7 includes a jaw 14, and a drive cylinder is installed at the opening and closing control end of the jaw 14 to adjust the distance between the jaws to accommodate steel bars with a diameter of 6~32mm to be welded.

[0032] The welding machine control module includes a PLC controller. The display output terminal of the PLC controller is equipped with a touch screen for parameter setting and operation status display. The sensor input terminal of the PLC controller is connected to a sensor module, which includes a vision sensor for detecting the position of the rebar to be welded and an infrared sensor for detecting the temperature of the weld point.

[0033] A method for welding multiple weld points of an arc-shaped steel mesh, applicable to multiple weld point welding devices for arc-shaped steel mesh, includes the following steps: (1) Parameter setting: The welding path, welding speed, welding current, power-on time and action parameters of each mechanism are set through the touch screen of the welding machine control module; (2) Overall positioning of the device: Start the walking mechanism, and the drive motor drives the entire device to move along the ground guide rail through the meshing of the transmission gear and the ground rack until it reaches the starting position of the target welding area; during this process, the guide wheel ensures the straightness of the movement trajectory; (3) Arc welding point positioning: control the arc welding mechanism to move along the arc track beam, and use the real-time position information fed back by the position sensor to accurately position the welding unit to the arc coordinates where the target welding point is located; (4) Approaching the welding point: Control the telescopic structure of the welding mechanism to push the welding clamping mechanism to extend towards the steel bar to be welded and adjust to a suitable welding distance; (5) Clamping and energizing: The drive cylinder of the welding clamping mechanism is controlled to drive the jaws to close and firmly clamp the steel bar to be welded, so that the welding positive and welding negative electrodes are in close contact with the surface of the steel bar; then, the welding machine control module connects the circuit according to the set parameters to perform energized welding. (6) Complete single-point welding: After the set welding time is reached, the welding machine control module cuts off the welding current, then controls the drive cylinder to release the gripper and retract the welding mechanism telescopic structure to disengage from the weld point; (7) Cyclic welding: Repeat steps (3) to (6) to drive the arc welding mechanism to move along the arc track beam and complete the welding operation of all preset arc welding points at the current straight position point by point; (8) Move to the next station: Control the walking mechanism to move the device to the next straight station and repeat steps (2) to (7) until all welding points on the entire arc-shaped steel mesh are completed.

[0034] Although some preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0035] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this application and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A multi-point welding device for arc-shaped steel mesh, characterized in that: The device includes a walking mechanism for moving the entire device along a straight track to adjust the relative position of the device and the arc-shaped steel mesh to be welded. The walking mechanism is connected to the bottom of a frame to support the main structure of the device. An arc-shaped steel beam is fixedly installed on the top of the frame, its curvature matching that of the arc-shaped steel mesh to be welded. An arc-shaped welding mechanism is slidably installed on the arc-shaped track beam, reciprocating along its arc-shaped trajectory to achieve welding coverage of different arc-shaped positions on the arc-shaped steel mesh. One end of the arc-shaped welding mechanism is connected to a telescopic welding structure, and the other end is connected to a welding clamping mechanism. The telescopic welding structure extends and retracts in a direction perpendicular to the arc-shaped track beam to adjust the distance between the welding clamping mechanism and the steel bar to be welded. The welding clamping mechanism is used to clamp and fix the steel bar to be welded.

2. The arc-shaped steel mesh multi-welding point welding device as described in claim 1, characterized in that: The welding clamping mechanism includes an adjustable clamping end, the size of which is adapted to the diameter of the reinforcing bar to be welded, so as to stabilize the position of the reinforcing bar during the welding process.

3. The arc-shaped steel mesh multi-welding point welding device as described in claim 2, characterized in that: The welding clamping mechanism includes clamps, and the opening and closing control end of the clamps is equipped with a drive cylinder for adjusting the distance between the clamps to accommodate steel bars with a diameter of 6~32mm to be welded.

4. The arc-shaped steel mesh multi-welding point welding device as described in claim 1, characterized in that: The welding clamping mechanism has a welding positive electrode and a welding negative electrode installed on both sides, which are used to provide pressure and circuit channels during the clamping process, and welding is achieved by heating with current and pressure.

5. The arc-shaped steel mesh multi-welding point welding device as described in claim 1, characterized in that: The walking mechanism, arc welding mechanism, welding mechanism telescopic structure, welding clamping mechanism, welding positive electrode, and welding negative electrode are electrically connected to the welding machine control module, which is used to control the coordinated action of each mechanism. This includes controlling the start, stop, and movement speed of the walking mechanism; controlling the movement trajectory and speed of the arc welding mechanism along the arc track beam; controlling the extension and retraction of the welding mechanism telescopic structure to adjust the welding position; controlling the clamping and releasing actions of the welding clamping mechanism; and controlling the energizing time, current magnitude, and welding parameters of the welding positive and negative electrodes.

6. The arc-shaped steel mesh multi-welding point welding device as described in claim 1, characterized in that: The walking mechanism includes a drive motor, the power output end of which is connected to a transmission gear. The transmission gear meshes with one side of a rack, and the drive motor drives the walking mechanism to move along the ground guide rail through the transmission gear. A guide wheel is installed on the other side of the rack to ensure the straightness of the walking trajectory.

7. The arc-shaped steel mesh multi-welding point welding device as described in claim 5, characterized in that: The arc-shaped track beam is equipped with a position sensor to detect the position information of the arc-shaped welding mechanism in real time, so as to feed the position information back to the welding machine control module and realize the control of the welding position.

8. The arc-shaped steel mesh multi-welding point welding device as described in claim 5, characterized in that: The telescopic structure of the welding mechanism is an electric push rod or a hydraulic cylinder, and the telescopic range of the electric push rod or hydraulic cylinder is controlled by the welding machine control module.

9. The arc-shaped steel mesh multi-welding point welding device as described in claim 5, characterized in that: The welding machine control module includes a PLC controller. The display output terminal of the PLC controller is equipped with a touch screen for parameter setting and operation status display. The sensing signal input terminal of the PLC controller is connected to a sensor module, which includes a vision sensor for detecting the position of the rebar to be welded and an infrared sensor for detecting the temperature of the weld point.

10. A method for welding multiple weld points of an arc-shaped steel mesh, applicable to the arc-shaped steel mesh multi-weld-point welding device as described in claims 1-9, characterized in that, Includes the following steps: (1) Parameter setting: The welding path, welding speed, welding current, energizing time and action parameters of each mechanism are set through the touch screen of the welding machine control module; (2) Overall positioning of the device: Start the walking mechanism, and the drive motor drives the entire device to move along the ground guide rail through the meshing of the transmission gear and the ground rack until it reaches the starting position of the target welding area; during this process, the guide wheel ensures the straightness of the movement trajectory; (3) Arc welding point positioning: control the arc welding mechanism to move along the arc track beam, and use the real-time position information fed back by the position sensor to accurately position the welding unit to the arc coordinates where the target welding point is located; (4) Approaching the welding point: Control the telescopic structure of the welding mechanism to push the welding clamping mechanism to extend towards the steel bar to be welded and adjust to a suitable welding distance; (5) Clamping and energizing: The drive cylinder of the welding clamping mechanism is controlled to drive the jaws to close and firmly clamp the steel bar to be welded, so that the welding positive and welding negative electrodes are in close contact with the surface of the steel bar; then, the welding machine control module connects the circuit according to the set parameters to perform energized welding. (6) Complete single-point welding: After the set welding time is reached, the welding machine control module cuts off the welding current, then controls the drive cylinder to release the gripper and retract the welding mechanism telescopic structure to disengage from the weld point; (7) Cyclic welding: Repeat steps (3) to (6) to drive the arc welding mechanism to move along the arc track beam and complete the welding operation of all preset arc welding points at the current straight position point by point; (8) Move to the next station: Control the walking mechanism to move the device to the next straight station and repeat steps (2) to (7) until all welding points on the entire arc-shaped steel mesh are completed.

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