Box girder steel formwork automatic rust removal system based on laser technology and using method

Abstract

The invention discloses an automatic box girder steel formwork rust removal system based on a laser technology and a using method. The system comprises a formwork support, a walking track, a door-type support, a laser generator, an air compressor, dust removal equipment and a control system. The gate-type support is located on walking rails on the two sides of the formwork support through walking wheels at the bottom and can move in the longitudinal direction of the formwork. A sliding table capable of moving transversely is installed on the door-type support, a sealing cover integrating a laser emitting end, a high-pressure gas nozzle and a dust removal suction port is hung at the bottom of the sliding table, and the sealing cover and the surface of the formwork form a closed operation cavity through a bottom flexible sealing edge. The system is further provided with a wall-climbing robot capable of moving and working on the vertical face of the formwork and a complex area, and the wall-climbing robot carries an integrated working head and is fixed in a magnetic adsorption or negative pressure adsorption mode. Through cooperative operation of the door-type support and the wall-climbing robot, efficient, high-quality and pollution-free automatic rust removal of the whole surface of the large box girder steel formwork is achieved, and the defects that a traditional method is low in efficiency, many in dead angle and large in pollution are overcome.

Description

Technical Field

[0001] This invention belongs to the field of construction engineering technology, specifically relating to an automated rust removal system for box girder steel formwork based on laser technology and its usage method. Background Technology

[0002] In civil engineering construction such as bridges and buildings, the steel formwork for box girders used in concrete pouring needs to be reused. After each demolding, concrete slurry remains on the formwork surface, leading to rust. Before the next use, it must be thoroughly ground and cleaned to ensure the quality of the concrete and the smoothness of the surface. Currently, the industry commonly uses handheld angle grinders or abrasive wheels for this grinding operation. While this method is simple and low-cost, it has significant drawbacks: 1. Extremely low construction efficiency: It relies entirely on manual labor, resulting in high labor intensity, slow cleaning speed, and impacting the overall project progress. 2. Harsh working environment: The grinding process generates a large amount of metal dust and noise, seriously endangering the health of workers. 3. High pollution: Dust permeates the area, causing serious pollution to the construction site and surrounding environment. 4. Inconsistent cleaning quality: It depends on the experience and responsibility of workers, making it difficult to ensure uniform grinding results for every section of the formwork.

[0003] While laser cleaning technology has been applied in high-precision manufacturing and ship repair, its technical objective is typically to achieve a rough substrate surface to enhance coating adhesion. However, in concrete construction, the technical objective is exactly the opposite: the sanded surface of the box girder steel formwork must be smooth and clean to ensure a smooth and aesthetically pleasing surface after concrete demolding. This fundamental difference in objectives has prevented the technology from being successfully introduced or adapted to the engineering construction field. Therefore, there is an urgent need for a new automated sanding technology and equipment that can overcome these shortcomings. Summary of the Invention

[0004] The purpose of this invention is to provide an automated rust removal system and method for box girder steel formwork based on laser technology, which aims to solve the technical problems of low construction efficiency, serious environmental pollution, great health hazards to workers, and uncontrollable grinding quality caused by reliance on manual labor in traditional technologies.

[0005] To achieve the above objectives, the present invention adopts the following technical solution.

[0006] An automated rust removal system for box girder steel formwork based on laser technology includes a formwork support and a laser generator; it also includes a traveling track, a portal frame, and a control system; the formwork support is attached to the bottom of the box girder steel formwork to be rusted, and a traveling track is longitudinally arranged on the formwork support on both sides of the box girder steel formwork; the portal frame spans across the box girder steel formwork, and traveling wheels are provided on both sides of the bottom of the portal frame; the traveling wheels are rotatably connected to the traveling track and are driven by a drive device to move along the traveling track; the laser generator is mounted on the portal frame; an air compressor, dust removal equipment, and a slider are also provided on the portal frame, and the slider is laterally movable; a first sealing cover is connected to the bottom of the slider via a telescopic rod; the first sealing cover integrates a first laser emitting end, a first high-pressure gas nozzle, and a first dust removal inlet; the first laser emitting end is connected to the laser generator via a first laser transmission fiber; the first high-pressure gas nozzle is connected to the air compressor via a first high-pressure air duct; the first dust removal inlet is connected to the dust removal equipment via a first dust removal pipe; a first flexible sealing edge is provided around the bottom of the first sealing cover; The drive unit, laser generator, air compressor, and dust removal equipment are electrically connected to the control system.

[0007] Preferably, the template support includes template support units and support plates; there are two template support units, which are respectively set at the bottom of both sides of the box girder steel template; the traveling track is set at the top of the template support units on both sides; the cross-sectional shape of the support plate is adapted to the cross-sectional shape of the box girder steel template to be derusted, and the two sides of the support plate overlap the template support units on both sides; the box girder steel template to be derusted is laid on the support plate.

[0008] Preferably, the two ends of the portal frame are supported on the travel track, and it includes a portal frame unit and a longitudinal beam; there are two portal frame units, arranged longitudinally at intervals; the two ends of each portal frame unit are connected to the travel track through travel wheels; the longitudinal beam connects the two portal frame units; the portal frame unit includes a crossbeam and a support; the support includes a central support body and connecting rods on both sides; the support body is U-shaped and located in the space between the two template support units; the connecting rods are respectively connected to the two ends of the support body, and the connecting rods on both sides are located above the two portal frame units; the two ends of the connecting rods are bent upward to form short vertical sections; the crossbeam is set above the support, and the connecting rod is connected to the crossbeam through the short vertical sections; diagonal braces and vertical rods are provided between the crossbeam and the support; a crossbeam is provided between the two vertical sides of the support body; the laser generator, air compressor, and dust removal equipment are fixed on the crossbeam, and the laser generator, air compressor, and dust removal equipment are powered by cables.

[0009] Preferably, it also includes a wall-climbing robot; the wall-climbing robot includes a wall-climbing robot body and an adsorption mechanism; the adsorption mechanism is adsorbed onto the box girder steel formwork, and the adsorption mechanism adopts negative pressure adsorption or magnetic adsorption; the wall-climbing robot carries an integrated working head; the working head includes a second laser emitting end, a second high-pressure gas nozzle and a second dust removal suction port; the second laser emitting end is connected to a laser generator through a second laser transmission optical fiber; the second high-pressure gas nozzle is connected to an air compressor through a second high-pressure air duct; the second dust removal suction port is connected to a dust removal device through a second dust removal pipe; a second sealing cover is provided on the outside of the second laser emitting end, the second high-pressure gas nozzle and the second dust removal suction port; a second flexible sealing edge is provided around the bottom of the second sealing cover.

[0010] Preferably, the adsorption mechanism is a magnetic adsorption mechanism, including an electromagnet mounted on the rollers of the wall-climbing robot.

[0011] Preferably, the adsorption mechanism is a negative pressure adsorption mechanism, including at least one negative pressure chamber disposed at the bottom of the wall-climbing robot body, a vacuum generating device for providing negative pressure to the negative pressure chamber, and a flexible sealing skirt disposed at the bottom of the negative pressure chamber; an independent vacuum sensor is disposed in the negative pressure chamber.

[0012] Preferably, the slider is mounted on the support body of the portal frame via a linear module; the linear module includes a guide rod, a screw, and a motor; connecting plates are respectively provided at the bottom and near both ends of the support body; the guide rod and the screw are connected in parallel between the connecting plates on both sides; one end of the screw is connected to the connecting plate via a bearing, and the other end of the screw protrudes from the corresponding connecting plate; the end of the screw protruding from the connecting plate is connected to the motor; the slider is mounted on the guide rod and the screw, and the slider and the screw are threaded together, the slider is sleeved on the guide rod, and can slide along the guide rod.

[0013] Preferably, a sensor array is mounted on the gantry bracket.

[0014] The method of using this laser-based automated rust removal system for box girder steel formwork includes the following steps.

[0015] Step 1: Construction preparation and site layout.

[0016] Step 2: Assemble the template support and lay the walking track.

[0017] Step 3: Install the gantry frame and auxiliary equipment: hoist the assembled gantry frame so that its bottom wheels are positioned on the travel tracks on both sides.

[0018] Step 4: System debugging and parameter setting.

[0019] Step 5: Start the air compressor and dust removal equipment to enable the high-pressure gas and dust removal system to start working.

[0020] Step Six: The system automatically performs the rust removal operation according to the preset program: a. The portal frame moves to the starting end of the box girder steel formwork under the drive of the drive device; b. The slider moves the first sealing cover to the horizontal starting position; c. Activate the telescopic rod to lower the first sealing cover and make the first flexible sealing edge fit against the surface of the box girder steel formwork to form a sealed cavity; d. The first laser emitting end emits laser light in the cavity to remove rust, while the first high-pressure gas nozzle blows away the molten material and dust, and the dust removal suction port instantly sucks the pollutants into the dust removal equipment; e. After completing one horizontal rust removal step, the slider drives the first laser emitting head to move horizontally by one step. f. Repeat step de until the entire template width is covered; g. The gantry bracket moves longitudinally by one step, then the slider moves in the opposite direction to perform the next round of transverse scanning; h. Repeat this process to remove rust from the entire upper surface of the template.

[0021] Step 7: Quality spot check.

[0022] Step 8: Operation completed and equipment removed from site.

[0023] Preferably, for areas on the vertical or inclined surfaces of the box girder steel formwork that cannot be covered by the portal frame, a wall-climbing robot is used for assisted rust removal. The wall-climbing robot is placed on the box girder steel formwork to be rusted, the adsorption mechanism is activated, and the wall-climbing robot is moved by the control system or remote control. The integrated working head carried by the wall-climbing robot performs laser rust removal, air blowing, and dust removal.

[0024] Compared with the prior art, the present invention has the following features and beneficial effects.

[0025] 1. The core of the automated rust removal system and method for box girder steel formwork based on laser technology of the present invention lies in using the high energy of laser to instantly ablate the rust layer on the surface of the formwork. The entire system has a high degree of automation, and operators do not need to come into close contact with the laser head and rust dust. At the same time, the system integrates high-pressure air blowing and negative pressure dust suction functions, realizing efficient, environmentally friendly and high-quality automated rust removal operations. And through remote monitoring and intervention by the control system, the health and safety of personnel are effectively guaranteed.

[0026] 2. This invention achieves highly efficient and large-scale automated operation. A gantry-type support moves longitudinally along tracks pre-laid on both sides of the formwork, combined with the lateral movement of its top sliding platform, forming a "gantry scanning" motion system covering the entire upper surface of the box girder steel formwork. This design allows the laser rust removal head to automatically and continuously complete large-area rust removal work in a zigzag path, completely changing the inefficiency and high labor intensity of traditional manual hand tools, significantly improving work efficiency. Simultaneously, laser rust removal is a non-contact processing method, causing no mechanical damage to the steel formwork substrate. It can precisely remove the rust layer while preserving the intact metal body, greatly improving the quality and consistency of rust removal and ensuring high-precision, high-quality rust removal results.

[0027] 3. This invention integrates a sealing cover and synchronous dust removal. The first sealing cover and its flexible sealing edge at the bottom can form a sealed cavity with the steel template surface during operation. This design confines the metal oxide dust and molten particles generated during laser rust removal within a sealed space, and through the integrated high-pressure gas nozzle and dust removal port, achieves "instant dispersion and instant suction," effectively preventing secondary pollution, ensuring the cleanliness of the work area, and also ensuring the effective transmission of laser energy.

[0028] 4. For complex areas such as facades, slopes, and corners that are difficult to cover with portal frames, this invention innovatively introduces a wall-climbing robot. The robot can choose between magnetic adsorption or negative pressure adsorption depending on the template material, carrying an integrated miniature working head to flexibly reach any location for rust removal. This combination of "main system - portal frame + auxiliary system - wall-climbing robot" achieves comprehensive rust removal of complex-shaped box girder steel templates without blind spots, solving the problem of poor adaptability of traditional equipment. Simultaneously, for the wall-climbing robot, this invention incorporates an independent vacuum sensor in the negative pressure adsorption mechanism to monitor the adsorption status in real time, ensuring operational safety; the flexible sealing skirt adapts to slightly uneven template surfaces, maximizing cavity sealing and providing reliable adsorption force.

[0029] 5. The portal frame in this invention employs a stable structure combining crossbeams, supports, longitudinal beams, and diagonal braces, ensuring overall rigidity and stability when supporting equipment such as laser generators and air compressors. The adaptability design of the template support and support plate provides a stable working platform for the entire system. The cooperation between the traveling wheels and the track ensures smooth and precise movement. Attached Figure Description

[0030] The present invention will now be described in further detail with reference to the accompanying drawings.

[0031] Figure 1 This is a structural schematic diagram of the automated rust removal system for box girder steel formwork of the present invention.

[0032] Figure 2 This is a schematic diagram of the portal frame structure in this invention.

[0033] Figure 3 This is a structural schematic diagram of the portal frame unit in this invention.

[0034] Figure 4 This is a schematic diagram of the structure of the first sealing cover of the present invention, which integrates a first laser emitting end, a first high-pressure gas nozzle and a first dust removal suction port.

[0035] Figure 5 This is a schematic diagram of the internal structure of the working head in this invention.

[0036] Figure 6 This is a schematic diagram of the structure in this invention where the first sealing cover is connected to the bottom of the portal frame unit via a sliding rod and a slider.

[0037] Figure 7 This is a schematic diagram of the wall-climbing robot when the adsorption mechanism is an electromagnet in this invention.

[0038] Figure 8 This is a schematic diagram of the wall-climbing robot when the adsorption mechanism is a negative pressure adsorption mechanism in this invention. Figure 9 This is a schematic diagram of the linear module in this invention.

[0039] Reference numerals: 1 - Template support, 1.1 - Template support unit, 1.2 - Support plate, 2 - Laser generator, 3 - Traveling track, 4 - Portal support, 4.1 - Portal support unit, 4.1.1 - Crossbeam, 4.1.2 - Support, 4.1.2a - Support body, 4.1.2b - Connecting rod, 4.1.2c - Short vertical section, 4.1.3 - Diagonal brace, 4.1.4 - Vertical rod, 4.1.5 - Crossbeam, 4.2 - Longitudinal beam, 5 - Box girder steel template, 6 - Traveling wheel, 7 - Air compressor, 8 - Dust removal equipment, 9 - Slider, 10 - First sealing cover, 11 - First laser emitting end, 12 - First high-pressure gas nozzle, 13 - First dust removal suction port, 14 - First laser transmission fiber, 15 - First high-pressure air duct, 16 – First dust removal duct; 17 – First flexible sealing edge; 18 – Wall-climbing robot; 18.1 – Wall-climbing robot body; 18.2 – Adsorption mechanism; 18.2.1 – Negative pressure chamber; 18.2.2 – Vacuum generating device; 18.2.3 – Flexible sealing skirt; 19 – Working head; 19.1 – Second laser emitting end; 19.2 – Second high-pressure gas nozzle; 19.3 – Second dust removal suction port; 19.4 – Second high-pressure air duct; 19.5 – Second dust removal duct; 19.6 – Second laser transmission fiber; 19.7 – Second sealing cover; 19.8 – Second flexible sealing edge; 23 – Guide rod; 24 – Screw; 26 – Motor; 27 – Connecting plate; 28 – Sensor group; 29 – Support plate; 30 – Telescopic rod. Detailed Implementation

[0040] like Figure 1-9 As shown, this automated rust removal system for box girder steel formwork based on laser technology includes a formwork support 1 and a laser generator 2. Its features include: a traveling track 3, a portal frame 4, and a control system; the formwork support 1 is supported at the bottom of the box girder steel formwork 5 to be rusted, and traveling tracks 3 are longitudinally arranged on the formwork support 1 on both sides of the box girder steel formwork 5; the portal frame 4 spans across the box girder steel formwork 5, and traveling wheels 6 are respectively provided on both sides of the bottom of the portal frame 4; the traveling wheels 6 are rotatably connected to the traveling tracks 3, and the traveling wheels 6 are driven by a drive device to move along the traveling tracks 3; the laser generator 2 is mounted on the portal frame 4; an air compressor 7, a dust removal device 8, and a slider 9 are also provided on the portal frame 4, and the laser generator 2, air compressor 7, and dust removal device 8 are integrated into the system. The dust removal device 8 is powered and transmits control signals via cables; the slider 9 is laterally movable; a first sealing cover 10 is connected to the bottom of the slider 9 via a telescopic rod 30; the telescopic rod 30 is an electric telescopic rod; the first sealing cover 10 integrates a first laser emitting end 11, a first high-pressure gas nozzle 12, and a first dust removal suction port 13; the first laser emitting end 11 is connected to the laser generator 2 via a first laser transmission fiber 14; the first high-pressure gas nozzle 12 is connected to the air compressor 7 via a first high-pressure air duct 15; the first dust removal suction port 13 is connected to the dust removal device 8 via a first dust removal pipe 16; a first flexible sealing edge 17 is provided around the bottom of the first sealing cover 10, which can form a cavity sealed to the surface of the box girder steel template 5 during operation; The drive device, laser generator 2, air compressor 7, and dust removal equipment 8 are electrically connected to the control system.

[0041] In this embodiment, the template support 1 includes a template support unit 1.1 and a support plate 1.2; there are two template support units 1.1, which are respectively set at the bottom of both sides of the box girder steel template 5; the walking track 3 is set at the top of the template support units 1.1 on both sides; the cross-sectional shape of the support plate 1.2 is adapted to the cross-sectional shape of the box girder steel template 5 to be derusted, and the two sides of the support plate 1.2 overlap the template support units 1.1 on both sides; the box girder steel template 5 to be derusted is laid on the support plate 1.2.

[0042] In this embodiment, the two ends of the portal frame 4 are respectively supported on the traveling track 3, and include a portal frame unit 4.1 and a longitudinal beam 4.2; there are two portal frame units 4.1, arranged longitudinally at intervals; the two ends of each portal frame unit 4.1 are respectively connected to the traveling track 3 through traveling wheels 6; the longitudinal beam 4.2 connects the two portal frame units 4.1; the portal frame unit 4.1 includes a crossbeam 4.1.1 and a support 4.1.2; the support 4.1.2 includes a central support body 4.1.2a and connecting rods 4.1.2b on both sides; the support body 4.1.2a is U-shaped and located in the space between the two template support units 1.1; the connecting rods 4.1.2b are respectively connected to the support body 4.1.2a. The two ends of the support 4.1.2a are connected to the support 4.1.2a, and the connecting rods 4.1.2b on both sides are located above the portal frame units 4.1 on both sides. The two ends of the connecting rods 4.1.2b are bent upward to form short vertical sections 4.1.2c. The crossbeam 4.1.1 is set above the support 4.1.2, and the connecting rods 4.1.2b are connected to the crossbeam 4.1.1 through the short vertical sections 4.1.2c. Diagonal bracing rods 4.1.3 and vertical rods 4.1.4 are set between the crossbeam 4.1.1 and the support 4.1.2. A crossbeam 4.1.5 is set between the two vertical sides of the support body 4.1.2a. The laser generator 2, air compressor 7 and dust removal equipment 8 are fixed on the crossbeam 4.1.5, and the laser generator 2, air compressor 7 and dust removal equipment 8 are powered by cables.

[0043] In this embodiment, a wall-climbing robot 18 is also included; the wall-climbing robot 18 includes a wall-climbing robot body 18.1 and an adsorption mechanism 18.2; the adsorption mechanism 18.2 is adsorbed onto the box girder steel formwork 5, and the adsorption mechanism 18.2 adopts negative pressure adsorption or magnetic adsorption; the wall-climbing robot 18 carries an integrated working head 19; the working head 19 is connected to the wall-climbing robot 18 through a mechanical arm, and the mechanical arm and the wall-climbing robot 18 are hinged together; the working head 19 includes a second laser emitting end 19.1, a second high-pressure gas nozzle 19.2, and a second dust removal suction port 19.3; The second laser emitting end 19.1 is connected to the laser generator 2 via the second laser transmission optical fiber 19.6; the second high-pressure gas nozzle 19.2 is connected to the air compressor 7 via the second high-pressure air duct 19.4; the second dust removal port 19.3 is connected to the dust removal equipment 8 via the second dust removal pipe 19.5; a second sealing cover 19.7 is provided on the outside of the second laser emitting end 19.1, the second high-pressure gas nozzle 19.2 and the second dust removal port 19.3; the second sealing cover 19.7 is hinged to the robotic arm, and a second flexible sealing edge 19.8 is provided around the bottom of the second sealing cover 19.7.

[0044] In this embodiment, both the first laser transmission fiber 14 and the second laser transmission fiber 19.6 are flexible laser transmission fibers.

[0045] In this embodiment, the adsorption mechanism 18.2 is a magnetic adsorption mechanism, including an electromagnet disposed on the rollers of the wall-climbing robot body 18.1, making the rollers of the wall-climbing robot body 18.1 electromagnetic wheels. After being energized, the electromagnet generates a strong magnetic field, forming a magnetic attraction force with the box girder steel template 5, thereby reliably adsorbing the wall-climbing robot 18 onto the template surface.

[0046] In this embodiment, the adsorption mechanism 18.2 is a negative pressure adsorption mechanism, including at least one negative pressure chamber 18.2.1 disposed at the bottom of the wall-climbing robot body 18.1, a vacuum generating device 18.2.2 for providing negative pressure to the negative pressure chamber 18.2.1, and a flexible sealing skirt 18.2.3 disposed at the bottom of the negative pressure chamber 18.2.1; an independent vacuum sensor is disposed in the negative pressure chamber 18.2.1; the negative pressure chamber 18.2.1 is a semi-sealed space with an opening at the bottom; when the wall-climbing robot body 18.1 is under construction, the box girder steel formwork 5 seals the opening of the negative pressure chamber 18.2.1, and together with the negative pressure chamber 18.2.1, forms a sealed space; the vacuum generating device 18.2.2 and the negative pressure chamber 18.2.1 are connected by a flexible hose. In this embodiment, the wall-climbing robot body 18.1 is a roller-mounted mobile robot with a long robotic arm, including a body structure, a mobility system, a control system, and an energy system; wherein, the body structure includes a frame, a robotic arm, and a shell; the mobility system includes rollers and drive motors; the control system includes a main controller and various sensors; and the energy system includes a battery and a power management system.

[0047] In this embodiment, the slider 9 is mounted on the support body 4.1.2a of the portal frame 4 via a linear module; the linear module includes a guide rod 23, a screw 24, and a motor 26; connecting plates 27 are respectively provided at the bottom and near both ends of the support body 4.1.2a; the guide rod 23 and the screw 24 are connected in parallel between the connecting plates 27 on both sides; one end of the screw 24 is connected to the connecting plate 27 via a bearing, and the other end of the screw 24 protrudes from the corresponding side of the connecting plate 27; the end of the screw 24 protruding from the connecting plate 27 is connected to the motor 26; the slider 9 is mounted on the guide rod 23 and the screw 24, and the slider 9 is threadedly connected to the screw 24; the slider 9 is sleeved on the guide rod 23 and can slide along the guide rod 23.

[0048] In this embodiment, the slider 9 is provided with a channel through which the screw 24 and the guide rod 23 pass; a thread is provided on the wall of the channel through which the screw 24 passes; and a support plate 29 for mounting the motor 26 is provided at the bottom of the portal bracket 4, on one side of the screw 24.

[0049] In this embodiment, a sensor group 28 is installed on the portal frame 4. The sensor group 28 includes a positioning sensor, a distance measuring sensor, and a vision sensor. The positioning sensor is used to accurately detect the longitudinal position of the portal frame 4 on the box girder steel formwork 5. The distance measuring sensor monitors the distance between the first flexible sealing edge 17 at the bottom of the first sealing cover 10 and the surface of the box girder steel formwork 5 to ensure a good sealing effect without excessive compression. The vision sensor is used to identify rusted areas and detect the surface quality after rust removal.

[0050] The method of using this laser-based automated rust removal system for box girder steel formwork includes the following steps.

[0051] Step 1: Construction preparation and site layout: Determine the storage location of the steel formwork for the box girder to be derusted, and clear the surrounding site to ensure sufficient operating space and a safe power supply environment; Inspect all equipment, including laser generator 2, air compressor 7, dust removal equipment 8, gantry support 4, wall-climbing robot 18, etc., to ensure they are in good condition.

[0052] Step 2: Assemble the template support 1 and lay the walking track 3; Place the two formwork support units 1.1 at the bottom design positions on both sides of the box girder steel formwork 5; The two sides of the support plate 1.2, whose cross-sectional shape matches that of the box girder steel formwork 5, are respectively attached to the formwork support units 1.1 on both sides.

[0053] The steel formwork 5 of the box girder to be derusted is hoisted and laid stably on the support plate 1.2.

[0054] On the top of the two side template support units 1.1, the walking track 3 is installed and fixed longitudinally to ensure that the track is straight and stable.

[0055] Step 3: Install the gantry frame 4 and auxiliary equipment: hoist the assembled gantry frame, including the gantry frame unit, longitudinal beams, transverse beams, supports, etc., so that the traveling wheels 6 at the bottom are placed on the traveling tracks 3 on both sides; The laser generator 2, air compressor 7, and dust removal equipment 8 are fixedly installed on the crossarm of the gantry bracket.

[0056] Cables and conduits connecting the various devices include: laser generator 2 connected via laser transmission fiber to a first laser emitting end 11 on a gantry slider and a second laser emitting end 19.1 on a wall-climbing robot 18.

[0057] The air compressor is connected to the first high-pressure gas nozzle and the second high-pressure gas nozzle via a high-pressure air duct.

[0058] The dust removal equipment 8 is connected to the first dust removal port and the second dust removal port through a dust removal pipe.

[0059] Step 4: System debugging and parameter setting: Set the rust removal process parameters in the control system interface, including laser power, scanning speed, spot overlap rate, gas pressure, dust removal wind speed, etc.

[0060] Manually control the gantry support 4 to travel back and forth along the track 3 for one round trip, and check for any jamming or interference.

[0061] Test the lateral movement function of slider 9 to ensure its smooth operation and that its stroke covers the entire width of the box girder steel formwork 5.

[0062] Activate all sensors, such as positioning sensors, ranging sensors, and vision sensors, calibrate their readings, and ensure they are functioning correctly.

[0063] Test the lifting and lowering of the first sealing cover 10 and the adhesion effect between the first flexible sealing edge at its bottom and the surface of the box girder steel formwork 5.

[0064] Step 5: Start the air compressor 7 and dust removal equipment 8 to enable the high-pressure gas and dust removal system to start working; Start the laser generator and put it into standby mode.

[0065] Select the automatic operation mode in the control system and issue a start command.

[0066] Step Six: The system automatically performs the rust removal operation according to the preset program: a. The portal frame 4 moves to the starting end of the box girder steel formwork 5 under the drive of the drive device.

[0067] b. Slider 9 moves the first sealing cover 10 to the horizontal starting position.

[0068] c. Adjust the telescopic rod 30 to lower the first sealing cover 10 and make the first flexible sealing edge 17 fit against the surface of the box girder steel formwork 5 to form a sealed cavity.

[0069] d. The first laser emitting end 11 emits laser light in the cavity to remove rust, while the first high-pressure gas nozzle 12 blows away the molten material and dust, and the dust removal suction port instantly sucks the pollutants into the dust removal equipment.

[0070] e. After completing one horizontal rust removal step, the slider 9 drives the first laser emitting end 11 to move horizontally by one step.

[0071] f. Repeat step de until the entire template width is covered.

[0072] g. The gantry bracket 4 moves longitudinally by one step, and then the slider 9 moves in the opposite direction to perform the next round of transverse scanning.

[0073] h. Repeat this process, using a zigzag path to complete the rust removal of the entire upper surface of the template.

[0074] Step 7: Process monitoring and quality spot checks; Throughout the rust removal process, operators can observe the equipment's operating status and the data fed back by various sensors in real time through the monitoring interface of the control system, such as position, distance, vacuum degree, etc.

[0075] Periodically stop the machine and conduct spot checks on the rust-removed template surface to verify whether the rust removal grade and cleanliness meet the standards. If the standards are not met, adjust the parameters in the control system and perform additional rust removal in that area.

[0076] Step 8: Operation completed and equipment removed from site.

[0077] The system will automatically stop once the entire template rust removal operation is completed.

[0078] Turn off the laser generator, air compressor, and dust removal equipment in sequence.

[0079] Move the gantry frame to a position at the end of the track that facilitates hoisting.

[0080] Disconnect all cables and conduits.

[0081] The gantry frame and related equipment are lifted off, the traveling rails and formwork supports are dismantled, and the support plates are recovered.

[0082] The construction site was cleaned up, and the rust-removed steel formwork for the box girders was transferred to the next process.

[0083] In this embodiment, for areas that cannot be covered by the vertical or inclined surfaces of the box girder steel formwork 5 or by the portal frame, a wall-climbing robot 18 is used for assisted rust removal. The wall-climbing robot 18 is placed on the box girder steel formwork 5 to be rusted, the adsorption mechanism 18.2 is activated, and the wall-climbing robot 18 is moved by the control system or remote control. The integrated working head carried by the wall-climbing robot 18 performs laser rust removal, air blowing, and dust removal.

[0084] If it is magnetic adsorption: then an electromagnet is energized, which generates a strong magnetic field, causing it to firmly adhere to the steel template.

[0085] If it is negative pressure adsorption: then the vacuum generating device is activated to generate negative pressure in the negative pressure chamber, and the flexible sealing skirt 18.2.3 is used to maintain the seal, thereby achieving adsorption.

[0086] In this embodiment, drive wheels are provided at the bottom of the wall-climbing robot 18, which drive the robot to move. A negative pressure chamber 18.2.1 is also provided at the bottom of the wall-climbing robot 18, which contacts the box girder steel formwork 5. This negative pressure chamber 18.2.1 is made of soft and wear-resistant rubber or polyurethane and serves as a negative pressure chamber or air chamber. The edge of this chamber is a sealing skirt, which adaptively conforms to the slightly uneven surface of the steel formwork to minimize air leakage. A turbine fan or a miniature vacuum pump is mounted on the body of the wall-climbing robot 18. During operation, the vacuum device is activated to continuously expel air from the negative pressure chamber. The wall-climbing robot 18 is then magnetically connected to the box girder steel formwork 5.

[0087] In this embodiment, when magnetic adsorption is used, electromagnets are installed on the rollers of the wall-climbing robot 18. The strong magnetic attraction between the electromagnets and the box girder steel template is used to fix the robot. The robot control system supplies current to the electromagnets, thereby achieving the adsorption of the electromagnets and the box girder steel templates. When the current is turned off, the magnetic force basically disappears, and the robot can detach.

[0088] The above embodiments are not exhaustive examples of specific implementation methods, and other embodiments are also possible. The purpose of the above embodiments is to illustrate the present invention, rather than to limit the scope of protection of the present invention. All applications derived from simple variations of the present invention fall within the scope of protection of the present invention.

Claims

1. An automated rust removal system for box girder steel formwork based on laser technology, comprising a formwork support (1) and a laser generator (2); characterized in that: It also includes a walking track (3), a portal frame (4), and a control system; the template support (1) is supported on the bottom of the box girder steel template (5) to be derusted, and a walking track (3) is set on the template support (1) and on both sides of the box girder steel template (5) along the longitudinal length; the portal frame (4) spans across the box girder steel template (5), and a walking wheel (6) is provided on both sides of the bottom of the portal frame (4); the walking wheel (6) is rolled on the walking track (3), and the walking wheel (6) is driven by a drive device to move along the walking track (3); the laser generator (2) is installed on the portal frame (4); an air compressor (7), a dust removal device (8), and a slider ( 9), and the slider (9) is movable in the lateral direction; a first sealing cover (10) is connected to the bottom of the slider (9) by a telescopic rod (30); the first sealing cover (10) integrates a first laser emitting end (11), a first high-pressure gas nozzle (12) and a first dust removal port (13); the first laser emitting end (11) is connected to the laser generator (2) through a first laser transmission fiber (14); the first high-pressure gas nozzle (12) is connected to the air compressor (7) through a first high-pressure air duct (15); the first dust removal port (13) is connected to the dust removal equipment (8) through a first dust removal pipe (16); a first flexible sealing edge (17) is provided around the bottom of the first sealing cover (10); The drive unit, laser generator (2), air compressor (7) and dust removal equipment (8) are electrically connected to the control system.

2. The automated rust removal system for box girder steel formwork based on laser technology according to claim 1, characterized in that: The template support (1) includes a template support unit (1.1) and a support plate (1.2); there are two template support units (1.1), which are respectively set at the bottom of both sides of the box girder steel template (5); the walking track (3) is set at the top of the template support units (1.1) on both sides; the cross-sectional shape of the support plate (1.2) is adapted to the cross-sectional shape of the box girder steel template (5) to be derusted, and the two sides of the support plate (1.2) overlap the template support units (1.1) on both sides respectively; the box girder steel template (5) to be derusted is laid on the support plate (1.2).

3. The automated rust removal system for box girder steel formwork based on laser technology according to claim 2, characterized in that: The two ends of the portal frame (4) are respectively supported on the traveling track (3), and include a portal frame unit (4.1) and a longitudinal beam (4.2); there are two portal frame units (4.1) arranged longitudinally at intervals; the two ends of each portal frame unit (4.1) are respectively connected to the traveling track (3) through traveling wheels (6); the longitudinal beam (4.2) is connected between the two portal frame units (4.1); the portal frame unit (4.1) includes a crossbeam (4.1.1) and a support (4.1.2); the support (4.1.2) includes a middle support body (4.1.2a) and connecting rods (4.1.2b) on both sides; the support body (4.1.2a) is U-shaped and located in the space between the template support units (1.1) on both sides; the connecting rods (4.1.2b) are respectively connected to the two ends of the support body (4.1.2a). The connecting rods (4.1.2b) on both sides are located above the portal frame units (4.1) on both sides respectively; the two ends of the connecting rod (4.1.2b) are bent upward to form short vertical sections (4.1.2c); the crossbeam (4.1.1) is set above the support (4.1.2), and the connecting rod (4.1.2b) is connected to the crossbeam (4.1.1) through the short vertical section (4.1.2c); a diagonal brace (4.1.3) and a vertical rod (4.1.4) are provided between the crossbeam (4.1.1) and the support (4.1.2); a crossbeam (4.1.5) is provided between the two vertical sides of the support body (4.1.2a); the laser generator (2), the air compressor (7) and the dust removal equipment (8) are fixed on the crossbeam (4.1.5), and the laser generator (2), the air compressor (7) and the dust removal equipment (8) are powered by cables.

4. The automated rust removal system for box girder steel formwork based on laser technology according to claim 1, characterized in that: It also includes a wall-climbing robot (18); the wall-climbing robot (18) includes a wall-climbing robot body (18.1) and an adsorption mechanism (18.2); the adsorption mechanism (18.2) is adsorbed onto the box girder steel formwork (5), and the adsorption mechanism (18.2) adopts negative pressure adsorption or magnetic adsorption; the wall-climbing robot (18) carries an integrated working head (19); the working head (19) includes a second laser emitting end (19.1), a second high-pressure gas nozzle (19.2) and a second dust removal suction port (19.3); the second laser emitting end (19.1) is connected to the wall-climbing robot body (18.1) and the wall-climbing robot body (18.2) is connected to the wall-climbing robot body (18.1) and the wall-climbing robot body (18.2) is connected to the wall-climbing robot body (18.1) and the wall-climbing robot body (18.2) is connected to the wall-climbing robot body (18.1) and the wall-climbing robot body (18.2) is connected to the wall-climbing robot body (18.1) and the wall-climbing robot body (18.2) is connected to the wall-climbing robot body (18.2 ... The laser is connected to the laser generator (2) via the second laser transmission fiber (19.6); the second high-pressure gas nozzle (19.2) is connected to the air compressor (7) via the second high-pressure air duct (19.4); the second dust removal port (19.3) is connected to the dust removal equipment (8) via the second dust removal pipe (19.5); a second sealing cover (19.7) is provided on the outside of the second laser emitting end (19.1), the second high-pressure gas nozzle (19.2) and the second dust removal port (19.3); a second flexible sealing edge (19.8) is provided around the bottom of the second sealing cover (19.7).

5. The automated rust removal system for box girder steel formwork based on laser technology according to claim 1, characterized in that: The adsorption mechanism (18.2) is a magnetic adsorption mechanism, including an electromagnet set on the roller of the wall-climbing robot body (18.1).

6. The automated rust removal system for box girder steel formwork based on laser technology according to claim 1, characterized in that: The adsorption mechanism (18.2) is a negative pressure adsorption mechanism, including at least one negative pressure chamber (18.2.1) disposed at the bottom of the wall-climbing robot body (18.1), a vacuum generating device (18.2.2) for providing negative pressure to the negative pressure chamber (18.2.1), and a flexible sealing skirt (18.2.3) disposed at the bottom of the negative pressure chamber (18.2.1); an independent vacuum sensor is disposed in the negative pressure chamber (18.2.1).

7. The automated rust removal system for box girder steel formwork based on laser technology according to claim 1, characterized in that: The slider (9) is mounted on the support body (4.1.2a) of the portal frame (4) via a set of linear modules; the linear modules include guide rods (23), screws (24) and motors (26); connecting plates (27) are respectively provided at the bottom and near both ends of the support body (4.1.2a); the guide rods (23) and screws (24) are connected in parallel between the connecting plates (27) on both sides; one end of the screw (24) is connected to the connecting plate (27) via a bearing, and the other end of the screw (24) passes through the corresponding connecting plate (27); one end of the screw (24) that passes through the connecting plate (27) is connected to the motor (26); the slider (9) is mounted on the guide rods (23) and screws (24), and the slider (9) is threadedly connected to the screws (24), the slider (9) is sleeved on the guide rods (23), and can slide along the guide rods (23).

8. The automated rust removal system for box girder steel formwork based on laser technology according to claim 1, characterized in that: The sensor group (28) is installed on the gantry bracket (4).

9. A method of using the automated rust removal system for box girder steel formwork based on laser technology as described in any one of claims 1-8, characterized in that, Includes the following steps: Step 1: Construction preparation and site layout; Step 2: Assemble the template support (1) and lay the walking track (3); Step 3: Install the gantry frame (4) and auxiliary equipment: hoist the assembled gantry frame so that its bottom wheels (6) are placed on the walking tracks (3) on both sides; Step 4: System debugging and parameter setting; Step 5: Start the air compressor (7) and dust removal equipment (8) to enable the high-pressure gas and dust removal system to start working; Step Six: The system automatically performs the rust removal operation according to the preset program: a. The portal frame (4) moves to the starting end of the box girder steel formwork (5) under the drive of the drive device; b. The slider (9) moves the first sealing cover (10) to the horizontal starting position; c. Activate the telescopic rod (30) to lower the first sealing cover (10) and make the first flexible sealing edge (17) fit against the surface of the box girder steel template (5) to form a sealed cavity; d. The first laser emitting end (11) emits laser light in the cavity to remove rust, while the first high-pressure gas nozzle (12) blows away the molten material and dust, and the dust removal port instantly sucks the pollutants into the dust removal equipment; e. After completing one horizontal rust removal step, the slider (9) drives the first laser emitting end (11) to move horizontally by one step. f. Repeat step de until the entire template width is covered; g. The gantry bracket (4) moves longitudinally by one step, and then the slider (9) moves in the opposite direction to perform the next round of transverse scanning; h. Repeat this process to remove rust from the entire upper surface of the template; Step 7: Quality spot check; Step 8: Operation completed and equipment removed from site.

10. The construction method of the automated rust removal system for box girder steel formwork based on laser technology according to claim 9, characterized in that: For areas on the vertical or inclined surfaces of the box girder steel formwork (5) that cannot be covered by the portal frame, a wall-climbing robot (18) is used for rust removal. The wall-climbing robot (18) is placed on the box girder steel formwork (5) to be rusted, and the adsorption mechanism (18.2) is activated. The wall-climbing robot (18) is moved by the control system or remote control. The integrated working head carried by the wall-climbing robot (18) performs laser rust removal, air blowing and dust removal operations.

Images