Steel structural member welding deformation correcting device
By combining a split roller and a high-frequency excitation system, the problems of unresolved internal stress and high equipment tonnage in the welding deformation of H-beams were solved, achieving a high-efficiency and springback-free correction effect.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-03-27
AI Technical Summary
In existing H-beam welding deformation correction technology, traditional correction methods fail to effectively eliminate internal residual stress, resulting in severe workpiece springback. Correction of thick plates requires excessively high equipment tonnage and has low correction efficiency.
It adopts a split roller design, combined with a high-frequency excitation system and anisotropic micro-ratchet texture. It eliminates internal residual stress through high-frequency pulse vibration and transverse shear force field, and uses the acoustic plastic effect to soften the metal lattice to achieve plastic deformation.
It significantly improves the straightening efficiency, ensures the stability of workpiece dimensions, avoids springback, reduces equipment tonnage requirements, and improves straightening accuracy and efficiency.
Smart Images
Figure CN121732609A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of metal structure manufacturing and processing equipment technology, specifically to a welding deformation correction device for steel structure components. Background Technology
[0002] In the manufacturing of modern steel structures, especially H-beams and columns, arc welding is the primary process for connecting the web and flanges. However, due to the shrinkage of the molten metal in the weld area during cooling, the enormous internal tensile stress causes adjacent flanges to collapse towards the web, a phenomenon known as "angular deformation" or "mushroom-shaped deformation." This geometric deviation severely affects the assembly accuracy and load-bearing capacity of the components and must be precisely corrected.
[0003] Existing angular deformation straightening technologies mainly rely on traditional mechanical roller straightening machines and flame straightening methods. Traditional roller straightening machines apply normal pressure perpendicular to the flange surface to the deformed area using one or more rows of straightening rollers, flattening the deformed part through forced bending. However, this simple pressure straightening method primarily focuses on restoring the geometric shape and fails to effectively eliminate residual longitudinal and transverse shrinkage stresses deeply embedded in the weld and heat-affected zone. When the workpiece leaves the straightening rollers, the remaining enormous stress often causes significant springback in the component, making it difficult to guarantee the dimensional stability after straightening. More seriously, for thick, high-strength H-beams, the equipment required for straightening using traditional roller pressing methods is extremely large, significantly increasing manufacturing costs and energy consumption. Furthermore, forced high-strain straightening can lead to excessive work hardening of the material surface, which is detrimental to subsequent processing and fatigue resistance of the component.
[0004] Another straightening method is flame straightening. Although it is relatively flexible in operation, its principle of inducing thermal stress deformation through localized heating is inefficient and overly reliant on the operator's experience and judgment, making it difficult to automate and scale up production. Furthermore, improper flame straightening carries the risk of damaging the metallographic structure of the steel. Summary of the Invention
[0005] To address the shortcomings of existing technologies, this invention provides a welding deformation correction device for steel structure components, which solves the problems of single correction force direction, failure to eliminate internal residual stress leading to severe workpiece springback, and excessively high equipment tonnage requirements for correcting thick plates in existing H-beam flange correction technologies.
[0006] To achieve the above objectives, the present invention provides the following technical solution: a welding deformation correction device for steel structure components, comprising a base, wherein a conveying roller assembly is provided on the upper part of the base for supporting the lower flange plate of the steel structure component and driving the steel structure component to move along the correction path; a synchronous lifting frame is provided on the outer side of the base, wherein two lifting ends of the synchronous lifting frame are symmetrically arranged on both sides of the base; each lifting end of the synchronous lifting frame is provided with a lower support assembly, which is used to support the lower surface of the upper flange plate and the web of the steel structure component; a crossbeam is fixedly connected to the top of the synchronous lifting frame, and a divergent pulse correction assembly is provided on the crossbeam for pressing the steel structure. On the upper surface of the upper flange plate of the component, the divergent pulse correction assembly includes two split rollers symmetrically arranged on both sides of the web plate of the steel structure component. The two split rollers are arranged in a divergent manner, so that the rotation axis of the rollers forms a forward angle with the travel direction of the steel structure component. The split rollers are equipped with an excitation mechanism, which is used to drive the split rollers to generate high-frequency pulse vibrations perpendicular to the surface of the flange plate. The surface of the split rollers in contact with the flange plate is provided with anisotropic micro-ratchet texture. The anisotropic micro-ratchet texture is configured to hinder the contraction of the surface metal of the flange plate towards the web plate during vibration and guide the surface metal to extend towards the edge of the flange plate.
[0007] Preferably, the split roller adopts a tapered roller structure, and the two split rollers are arranged at an outward V-angle to decompose the vertical pressure applied to the flange into a vertical component force and a horizontal component force extending laterally outward along the flange.
[0008] Preferably, the anisotropic micro-ratchet texture is a micron-level directional sawtooth structure, the sawtooth structure including a blocking surface and a guiding surface, wherein the blocking surface faces the web side of the steel structure member and is used to lock the inward displacement of the surface metal under the pressure of the split roller, and the guiding surface faces the edge side of the flange of the steel structure member and is used to guide the surface metal to generate directional plastic flow under the pressure of the split roller and the action of the horizontal component force.
[0009] Preferably, the divergent pulse correction assembly further includes a hydraulic cylinder and an elastic coupling seat. The split roller is connected to the output end of the hydraulic cylinder through the elastic coupling seat. The connection between the elastic coupling seat and the hydraulic cylinder is a ball joint structure. The top end of the hydraulic cylinder is fixedly connected to the crossbeam. The elastic coupling seat is provided with a nonlinear stiffness elastic element, which is configured to allow the split roller to generate a reciprocating displacement in the vertical direction following the excitation frequency, and to form an alternating contact state of compression and relaxation between the split roller and the flange plate.
[0010] Preferably, the split roller includes a guide frame, an outer roller sleeved on the outside of the guide frame and rotatably connected thereto, and an excitation mechanism passing through the center of the guide frame and rotatably connected thereto. The three are coaxially arranged. The guide frame is fixedly connected to upper supports at both ends. The top of the upper supports is fixedly connected to an elastic coupling seat. A rectangular guide groove is opened at the bottom of the guide frame. A roller is embedded in the guide groove. A high-frequency return spring is also provided between the roller and the guide groove. The excitation mechanism directly transmits impact energy to the outer roller through the roller.
[0011] Preferably, the excitation mechanism includes an excitation spindle, with both ends of the excitation spindle passing through and rotatably connected to both ends of the guide frame, and one end of the excitation spindle is fixedly connected to a motor. A cam is fixedly connected to the outer wall of the excitation spindle. Under the action of a high-frequency return spring, the outer circumference of the roller fits against the outer circumference of the cam and rotates with the cam. The roller reciprocates in the guide groove to apply a pulse force in a direction perpendicular to the surface of the flange.
[0012] Preferably, an external gear ring is fixedly connected to the outer wall of one end of the outer roller, and a gear is meshed with the tooth end of the external gear ring. A second motor is fixedly connected to the center of the gear, and the outer wall of the second motor is fixedly connected to the outer wall of the upper bracket.
[0013] Preferably, the lower support assembly includes a lower bracket, which is fixedly connected to the lifting end of the synchronous lifting frame. A support frame is slidably connected inside the lower bracket, and a screw mechanism is provided between the two. A lower support roller group is fixedly connected to one side of the two support frames. The screw mechanism drives the support frame to move on the lower bracket, so that the lower support roller group approaches or approaches the steel structure component.
[0014] This invention provides a device for correcting welding deformation in steel structure components. It has the following beneficial effects: This invention integrates a high-frequency excitation system within a split roller, utilizing the "acousto-plastic effect" induced by high-energy ultrasound or high-frequency vibration to soften the metal lattice. This high-frequency energy injection temporarily lowers the yield strength of the flange material within the straightening zone, facilitating dislocation slip. Therefore, the device requires only a small mechanical pressing force to achieve significant plastic deformation. Furthermore, because internal residual stress is released and homogenized during vibration, the workpiece exhibits almost no elastic rebound after exiting the straightening machine, significantly improving the dimensional stability of the component. Simultaneously, a kinematic design combining an outward-pointing divergent arrangement with tapered rollers is employed. Utilizing the differential velocity characteristic of the outer surface of the rollers being greater than the inner surface velocity, and the lateral component force generated by the divergence angle, a continuously outward-stretching shear force field is constructed on the flange surface. This actively introduced lateral plastic rheology directly counteracts and offsets the shrinkage tension generated by weld cooling, eliminating the internal cause of flange collapse from its mechanical source, rather than merely repairing the geometric appearance. Anisotropic micro-ratchet textures are precisely machined onto the surface of the split rollers. These tiny teeth embed themselves into the metal surface upon contact, forming countless microscopic "anti-reverse valves." On the one hand, this significantly enhances the roller's grip on the metal as it is pushed outward; on the other hand, it locks in the minute lateral stretching of the material. This ensures that the amount of plastic deformation generated by each vibration impact and mechanical rolling is effectively preserved, greatly improving the straightening efficiency. Attached Figure Description
[0015] Figure 1 This is a perspective view of the present invention; Figure 2 for Figure 1 Enlarged view of point A in the middle; Figure 3 This is a schematic diagram of the device in this invention loading steel structural components; Figure 4 This is a schematic diagram of the structure of the divergent pulse correction component in this invention; Figure 5 This is a partial structural diagram of the split roller in this invention; Figure 6 This is a cross-sectional schematic diagram of the split roller in this invention.
[0016] The components include: 1. Base; 2. Conveying roller assembly; 3. Synchronous lifting frame; 4. Lower support assembly; 401. Lower bracket; 402. Lower support roller assembly; 5. Crossbeam; 6. Split roller; 601. Guide frame; 602. Outer roller; 603. Excitation spindle; 604. Upper bracket; 605. Guide groove; 606. Roller; 607. High-frequency return spring; 608. Cam; 609. Motor 1; 610. External gear ring; 611. Gear; 612. Motor 2; 7. Hydraulic cylinder; 8. Elastic coupling seat. Detailed Implementation
[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0018] Please see the appendix Figure 1 - Appendix Figure 6 This invention provides a welding deformation correction device for steel structure components, based on a micro-impact step creep mechanism, specifically designed to solve the flange angle deformation problem of steel structure components such as H-beams after welding and cooling, i.e., the plastic deformation of the flange collapsing towards the web. The device includes a base 1, with a conveying roller group 2 mounted on the upper part of the base 1 to support the lower flange of the steel structure component and drive the component to move along the correction path. A synchronous lifting frame 3 is mounted on the outer side of the base 1, with two lifting ends symmetrically arranged on both sides of the base 1. Each lifting end of the synchronous lifting frame 3 is equipped with a lower support assembly 4, which supports the lower surface of the upper flange of the steel structure component and the web. A crossbeam 5 is fixedly connected to the top of the synchronous lifting frame 3, and a divergent pulse correction assembly is mounted on the crossbeam 5 to press the upper surface of the upper flange of the steel structure component. The straightening assembly includes two split rollers 6 symmetrically arranged on both sides of the web of the steel structure member. The two split rollers 6 are arranged in a divergent manner, so that the rotation axis of the rollers forms a forward angle with the travel direction of the steel structure member. The split rollers 6 are equipped with an excitation mechanism, which is used to drive the split rollers 6 to generate high-frequency pulse vibration perpendicular to the surface of the flange. The surface of the split rollers 6 in contact with the flange is provided with anisotropic micro-ratchet texture. The anisotropic micro-ratchet texture is configured to hinder the contraction of the surface metal of the flange towards the web and guide the surface metal to extend towards the edge of the flange during vibration. The lower support assembly 4 includes a lower bracket 401, which is fixedly connected to the lifting end of the synchronous lifting frame 3. A support frame is slidably connected inside the lower bracket 401, and a screw mechanism is provided between the two. A lower support roller group 402 is fixedly connected to one side of the two support frames. The screw mechanism drives the support frame to move on the lower bracket 401, so that the lower support roller group 402 approaches or approaches the steel structure component.
[0019] To ensure stable reaction force support during the correction operation, the device adopts a gantry-type rigid layout, that is, the symmetrically arranged synchronous lifting frame 3 serves as the side column, which, together with the crossbeam 5 and the base 1, forms a closed mechanical load-bearing ring.
[0020] The H-beam to be straightened is placed on the conveyor roller group 2 with its web vertical and flanges horizontal. The lower support assembly 4 provides lateral support to the web, ensuring that the centerline of the H-beam's web always coincides with the centerline of the device, thus guaranteeing uniform stress on both flanges. To ensure the H-beam is centered upon entering the device, adjustable lateral guide wheels can be installed at both the feed and discharge ends of the conveyor roller group 2 to further ensure the correct path of the H-beam.
[0021] The divergent pulse straightening assembly, located below the crossbeam 5, is the core operating unit of this device. To accommodate the symmetrical cross-sectional characteristics of the H-beam, the divergent pulse straightening assembly is divided into two groups, symmetrically arranged on both sides of the web of the H-beam, respectively pressing against the upper surfaces of the left and right flanges. This symmetrical arrangement counteracts the lateral thrust generated during the straightening process, preventing wavy buckling of the web.
[0022] Each set of divergent pulse straightening components is connected to the crossbeam 5 via a hydraulic cylinder 7. The hydraulic cylinder 7 is mounted vertically, with its piston rod end connected to the straightening component. The function of the hydraulic cylinder 7 is to provide the basic static straightening pressure, establishing an initial clamping contact between the straightening component and the flange plate, and adjusting the pressure amount according to the flange plate thickness. It should be noted that this static pressure is primarily used to overcome the elastic deformation range of the material, while the dynamic energy causing plastic rheology is provided by the pulse force generated within the straightening component.
[0023] In the vertical projection position, the upper divergent pulse correction component and the lower support component 4 maintain a strict correspondence. Specifically, the pressure center line of the divergent pulse correction component falls within the support range of the lower support component 4, forming a closed force flow loop. This arrangement ensures that the correction force acts directly on the thickness direction of the flange, achieving a high degree of concentrated energy utilization.
[0024] In addition, the device is equipped with a detection feedback system. Laser displacement sensors are installed at the feed and discharge ends of the conveyor roller group 2 to scan the deformation angle and flatness of the H-beam flange in real time. This data is fed back to the central control unit to dynamically adjust the extension of the main pressurizing hydraulic cylinder and the operating parameters of the divergent pulse correction component, which will be detailed later, thus achieving adaptive control of the correction process.
[0025] The split roller 6 adopts a tapered roller structure. The two split rollers 6 are arranged at an outward V-shaped angle, which decomposes the vertical pressure applied to the flange into a vertical component force and a horizontal component force that extends outward along the flange.
[0026] The divergent pulse straightening assembly, serving as the mechanical carrier for executing the micro-impact stepping creep mechanism, abandons the traditional single integral cylindrical roller design found in straightening machines, instead employing two symmetrically arranged split rollers 6. These two split rollers 6 are installed independently, corresponding to the inner and outer halves of the H-beam's single-sided flange, respectively. The split rollers 6 are designed as tapered rollers, with a ball-joint connection structure, ensuring line contact between their tapered generatrix and the upper surface of the flange. This tapered design compensates for the geometric height difference caused by the inclined installation of the split rollers 6, ensuring a uniform distribution of contact pressure.
[0027] To achieve lateral stretching of the surface metal of the flange plate, the two split rollers 6 are arranged in a divergent "V"-shaped inclination in space. Specifically, the rotation axis of the split rollers 6 is not parallel to the lateral axis in the horizontal plane, but forms a preset forward angle α with the lateral axis. Under the constraint of the forward angle α, the linear velocity vector of the split rollers 6 at the rotation tangent point no longer simply points in the direction of travel of the H-beam, but is decomposed into a longitudinal velocity component pointing in the direction of travel and a lateral velocity component pointing outward from the edge of the flange plate.
[0028] Based on the above arrangement, when the hydraulic cylinder 7 applies a total downward vertical pressure, a mechanical decomposition effect occurs at the contact interface between the split roller 6 and the flange plate. The vertical pressure is forcibly decomposed into two orthogonal components: one is a normal clamping force perpendicular to the flange plate surface, used to maintain the embedding depth of the micro-ratchets; the other is a transverse shear force pointing outward along the flange plate plane. The direction of this transverse shear force is diametrically opposed to the direction of the tensile stress generated by the cooling shrinkage of the H-beam weld, thereby constructing an external tensile field that counteracts weld shrinkage.
[0029] The divergent pulse correction assembly also includes a hydraulic cylinder 7 and an elastic coupling seat 8. The split roller 6 is connected to the output end of the hydraulic cylinder 7 through the elastic coupling seat 8. The connection between the elastic coupling seat 8 and the hydraulic cylinder 7 is a ball joint structure. The top of the hydraulic cylinder 7 is fixedly connected to the crossbeam 5. The elastic coupling seat 8 is equipped with a nonlinear stiffness elastic element, which is configured to allow the split roller 6 to generate a reciprocating displacement in the vertical direction following the excitation frequency, and to form an alternating contact state of compression and relaxation between the split roller 6 and the flange plate. The split roller 6 includes a guide frame 601, an outer roller 602 sleeved on the outside of the guide frame 601 and rotatably connected thereto, and an excitation mechanism passing through the center of the guide frame 601 and rotatably connected thereto. The three are coaxially arranged. The guide frame 601 is fixedly connected to an upper bracket 604 at both ends. The top of the upper bracket 604 is fixedly connected to an elastic coupling seat 8. A rectangular guide groove 605 is opened at the bottom of the guide frame 601. A roller 606 is embedded in the guide groove 605. A high-frequency return spring 607 is also provided between the roller 606 and the guide groove 605. The excitation mechanism directly transmits impact energy to the outer roller 602 through the roller 606. The vibration mechanism includes a vibration spindle 603, with both ends of the spindle 603 passing through and rotatably connected to both ends of the guide frame 601. One end of the spindle 603 is fixedly connected to a motor 609. A cam 608 is fixedly connected to the outer wall of the vibration spindle 603. Under the action of a high-frequency return spring 607, the outer circumference of a roller 606 engages with the outer circumference of the cam 608 and rotates with the cam 608. The roller 606 reciprocates within the guide groove 605, applying a pulse force in a direction perpendicular to the flange surface. An external gear ring 610 is fixedly connected to the outer wall of one end of the outer roller 602. A gear 611 meshes with the teeth of the external gear ring 610. A motor 612 is fixedly connected to the center of the gear 611. The outer wall of the motor 612 is fixedly connected to the outer wall of the upper support 604.
[0030] Each split roller 6 is driven by an independent motor 612, which has a matching reducer. The control system sets the rotational linear speed of the split roller 6 to be slightly greater than the travel speed of the H-beam, and the speed ratio between the two is usually set between 1.05 and 1.10.
[0031] The design intent of this speed difference is to create a continuous forward slippage phenomenon. Because the surface speed of the split roller 6 is faster than the workpiece surface speed, relative sliding friction occurs at the instant of contact. This sliding friction generates frictional heat, increasing the local temperature of the metal in the contact area and helping to reduce the material's resistance to deformation. Furthermore, the frictional force component along the discharge direction helps overcome the feed resistance during the straightening process, ensuring the continuity and stability of the processing.
[0032] Furthermore, the installation structure of the split roller 6 is based on a gantry-type rigid layout, ensuring that the split roller 6 can withstand high-frequency impact reaction forces from the vertical direction and huge shear forces from the horizontal direction. By adjusting the size of the front tension angle α, the ratio of the lateral shear force to the vertical clamping force can be precisely controlled to adapt to H-beam materials with different thicknesses and yield strengths, thus achieving vectorized control of the straightening force.
[0033] To introduce high-frequency impact energy into the correction interface and achieve microscopic stress relief, the split roller 6 is designed as a hollow shell structure with an integrated vibration excitation mechanism. This excitation mechanism, as an independent power source, is mechanically decoupled from the power system that drives the split roller 6 to rotate and feed, ensuring independent adjustment of the vibration frequency and feed speed.
[0034] The excitation mechanism is installed in the internal cavity of the split roller 6 and mainly consists of a high-speed excitation main shaft 603, a cam 608, a guide frame 601, and rollers 606. The excitation main shaft 603 passes coaxially through the guide frame 601 and is driven to rotate by an external high-speed motor 609. The cam 608 is fixed on the excitation shaft, and its outer contour maintains rolling contact with the rollers 606. When the excitation main shaft 603 rotates at high speed, the cam 608 drives the rollers 606 to periodically push the inner wall of the outer roller 602 outward.
[0035] This endogenous excitation structure allows the impact energy to act directly on the outer roller 602 and be transmitted to the flange surface, avoiding the energy attenuation caused by the transmission of energy through the long shaft or frame in traditional external vibrators. More importantly, the excitation force is directly converted into high-frequency pulse pressure perpendicular to the flange surface, which induces microscopic slippage of the material lattice in the contact area using the wave effect, thereby temporarily reducing the yield strength of the metal material.
[0036] The split roller 6 is connected to the hydraulic cylinder 7 via an elastic coupling seat 8, rather than a rigid connection. The elastic coupling seat 8 forms a flexible interface connecting the stationary crossbeam 5 and the vibrating split roller 6. The internal cavity of the elastic coupling seat 8 contains nonlinear stiffness elastic elements, specifically multi-layered stacked disc spring assemblies or high-damping polyurethane modules. These elastic elements provide elastic floating space in the vertical direction.
[0037] Based on the above structure, when the built-in excitation mechanism is working, the split roller 6 is not in a constant pressed position, but rather generates a slight reciprocating displacement in the vertical direction following the excitation frequency, i.e., jumping. The nonlinear stiffness elastic element plays a dual role in this process: on the one hand, it allows the split roller 6 to displace downwards during the excitation stroke to generate peak impact force; on the other hand, it quickly lifts the split roller 6 upwards during the return stroke through elastic restoring force, assisting the split roller 6 to disengage from the tight engagement state with the flange plate.
[0038] The aforementioned structure establishes a rapidly cyclical alternating contact state between the split roller and the flange plate, ranging from high-pressure impact to elastic unloading. This change in contact state forms the kinematic basis for the stepping creep mechanism described later, as it provides periodic opportunities for the microstructures on the surface of the split roller 6 to engage and disengage. Simultaneously, the elastic coupling seat 8 effectively isolates the reverse transmission of high-frequency vibrations to the hydraulic cylinder 7, protecting the hydraulic components from vibration fatigue damage and ensuring the long-term reliability of the device.
[0039] The anisotropic micro-ratchet texture is a micron-level directional sawtooth structure. The sawtooth structure includes a blocking surface and a guiding surface. The blocking surface faces the web side of the steel structure member and is used to lock the inward displacement of the surface metal under the pressing state of the split roller 6. The guiding surface faces the edge side of the flange of the steel structure member and is used to guide the surface metal to generate directional plastic flow under the pressing of the split roller 6 and the action of the horizontal component force.
[0040] To transform disordered vibrational energy into ordered plastic flow of metal, the conical surface of the split roller 6 in contact with the H-beam flange is not conventionally smooth and finely ground. Instead, it is processed with a high-hardness, anisotropic micro-ratchet texture using laser micro-engraving or precision rolling processes. This texture appears as a high-density, directional sawtooth array at the microscale, and its geometric characteristics directly determine the unidirectionality of metal rheology during the straightening process.
[0041] Each microstructural unit of the anisotropic micro-ratchet texture is an asymmetrical triangular cross-section, composed of two surfaces with specific angular functions: a steep, almost perpendicular, blocking surface and a gently sloping guide surface. The spatial orientation of these two surfaces follows strict logical rules: the blocking surface uniformly faces the web side of the H-beam, i.e., the direction of weld shrinkage, while the guide surface uniformly faces the free edge side of the flange. This specific geometric orientation design physically and mechanically creates a "one-way valve" effect for metal surface flow. When the split roller 6 is instantly pressed into the flange surface by the excitation mechanism, the micro-ratchets pierce the oxide layer and embed a small amount into the base metal. At this moment, the steep blocking surface forms a rigid mechanical engagement with the metal matrix, creating an anchoring boundary capable of withstanding enormous shear forces. The function of this boundary is that when the internal tensile stress generated by weld cooling attempts to pull the flange metal inward, the blocking surface provides absolute physical restraint, forcibly locking the inward displacement tendency of the metal.
[0042] Meanwhile, the gentle guide ramp acts as a rheological channel. Combined with the lateral force generated by the split roller 6, the surface metal, in a high-energy metastable state, cannot overcome the inner obstruction surface and can only slide and extend outwards along the path of least resistance, i.e., the slope direction of the guide ramp. This microstructure ensures that the plastic deformation caused by each vibration impact is completely converted into effective elongation to counteract weld shrinkage, rather than ineffective elastic oscillations.
[0043] Furthermore, to ensure the geometric accuracy and wear resistance of the micro-ratchets under long-term high-frequency impact and severe friction, the surface of the split roller 6 undergoes a special surface hardening treatment, such as supersonic flame spraying of tungsten carbide coating or deep ion nitriding treatment, making its surface hardness significantly higher than that of the substrate hardness of the H-beam steel flange. This hardness difference is a material science prerequisite for the smooth insertion of the micro-ratchets and their guiding function, preventing premature wear or flattening of the texture when straightening high-strength steel.
[0044] Through the above structure, the macroscopic continuous rolling is decomposed into a high-frequency, discrete "impact-rheology-stepping" micro-cycle. When the H-beam enters the straightening area, the hydraulic cylinder 7 applies a preload, the built-in vibration mechanism is activated, and the divergent pulse straightening component immediately enters the adaptive working state.
[0045] During the loading phase of each vibration cycle, the built-in excitation mechanism drives the split roller 6 to overcome the damping force of the elastic coupling seat 8 and impact the flange surface downwards with extremely high acceleration. This instantaneous high-energy impact generates an acoustic-plastic effect inside the metal, and the high-frequency vibration energy is directly transferred to the interior of the crystal lattice, activating dislocation motion and reducing dislocation pinning energy. This causes the yield strength of the flange surface metal to decrease significantly in a very short time, entering a high-energy metastable state that is highly sensitive to deformation.
[0046] Following the impact, the anisotropic micro-ratchet texture on the surface of the split roller 6 pierces the oxide scale on the flange surface, embedding a small amount into the temporarily softened base metal to form a rigid mechanical engagement point. At this moment, due to the outward V-shaped arrangement of the split roller 6, the enormous vertical pulse pressure applied to the flange is forcibly decomposed by the geometry, generating a strong shear force extending laterally outward along the flange. This shear force acts as an active driving source, attempting to drag the surface metal outward.
[0047] Under this high-pressure shearing condition, the one-way valve function of the anisotropic micro-ratchet texture plays a crucial role. The steep blocking surface on the inner side of the micro-ratchet tightly hooks into the metal matrix, physically blocking the path of metal retraction towards the web due to weld shrinkage stress or elastic rebound. Constrained by this boundary condition, the softened surface metal can only follow the gentle guide slope on the outer side of the micro-ratchet, undergoing directional plastic flow driven by the transverse shear force. This microscopic transverse extension directly counteracts and cancels the transverse and longitudinal shrinkage stresses generated by weld cooling, eliminating the intrinsic cause of angular deformation at the root of the stress field.
[0048] Then, during the unloading phase of the vibration cycle, the elastic coupling seat 8 rapidly rebounds using the potential energy stored in its internal elastic element, lifting the split roller 6 upwards. At this moment, the contact pressure between the roller and the flange plate is released instantaneously, and the micro-ratchet texture disengages from its engagement with the metal. During this extremely short interval, the roller undergoes a slight positional slip relative to the continuously fed H-beam surface, completing one "stepping" motion and preparing its position for the impact of the next cycle.
[0049] By repeating the cycle of "impact softening—locking extension—elastic reset," countless micron-level directional plastic flows accumulate macroscopically to create a significant corrective effect. The flange is gradually smoothed and extended outward without being subjected to excessive overall bending moment. Simultaneously, this high-frequency mechanical impact process is similar to ultrasonic shot peening, correcting the geometry while refining the surface grains of the flange and introducing a beneficial residual compressive stress layer, thus achieving high-precision, springback-free correction without damaging material properties.
[0050] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A welding deformation correction device for steel structure components, comprising a base (1), characterized in that, The base (1) is provided with a conveying roller group (2) on its upper part, which is used to support the lower flange plate of the steel structure component and drive the steel structure component to move along the correction path. The base (1) is provided with a synchronous lifting frame (3) on its outer side. The two lifting ends of the synchronous lifting frame (3) are symmetrically arranged on both sides of the base (1). The two lifting ends of the synchronous lifting frame (3) are provided with a lower support assembly (4). The lower support assembly (4) is used to support the lower surface of the upper flange plate and the web plate of the steel structure component. The top of the synchronous lifting frame (3) is fixedly connected with a crossbeam (5). The crossbeam (5) is provided with a divergent pulse correction assembly, which is used to press the upper surface of the upper flange plate of the steel structure component. The divergent pulse correction assembly includes two split rollers (6) symmetrically arranged on both sides of the web of the steel structure member. The two split rollers (6) are arranged in a divergent manner, so that the rotation axis of the rollers forms a forward angle with the travel direction of the steel structure member. The split rollers (6) are provided with an excitation mechanism inside. The excitation mechanism is used to drive the split rollers (6) to generate high-frequency pulse vibration perpendicular to the surface of the flange plate. The surface of the split rollers (6) in contact with the flange plate is provided with anisotropic micro ratchet texture. The anisotropic micro ratchet texture is configured to hinder the contraction of the surface metal of the flange plate towards the web plate and guide the surface metal to extend towards the edge of the flange plate during vibration.
2. The steel structure component welding deformation correction device according to claim 1, characterized in that, The split roller (6) adopts a tapered roller structure. The two split rollers (6) are arranged at an outward V-shaped angle, which decomposes the vertical pressure applied to the flange into a vertical component and a horizontal component that extends outward along the flange.
3. The steel structure component welding deformation correction device according to claim 1, characterized in that, The anisotropic micro-ratchet texture is a micron-level directional sawtooth structure. The sawtooth structure includes a blocking surface and a guiding surface. The blocking surface faces the web side of the steel structure member and is used to lock the inward displacement of the surface metal under the pressing state of the split roller (6). The guiding surface faces the edge side of the flange of the steel structure member and is used to guide the surface metal to generate directional plastic flow under the pressing of the split roller (6) and the action of the horizontal component force.
4. The steel structure component welding deformation correction device according to claim 1, characterized in that, The divergent pulse correction assembly also includes a hydraulic cylinder (7) and an elastic coupling seat (8). The split roller (6) is connected to the output end of the hydraulic cylinder (7) through the elastic coupling seat (8). The connection between the elastic coupling seat (8) and the hydraulic cylinder (7) is a ball joint structure. The top of the hydraulic cylinder (7) is fixedly connected to the crossbeam (5). The elastic coupling seat (8) is provided with a nonlinear stiffness elastic element, which is configured to allow the split roller (6) to generate a reciprocating displacement in the vertical direction following the excitation frequency, and to form an alternating contact state of compression and relaxation between the split roller (6) and the flange plate.
5. The steel structure component welding deformation correction device according to claim 4, characterized in that, The split roller (6) includes a guide frame (601), an outer roller (602) sleeved on the outside of the guide frame (601) and rotatably connected thereto, and an excitation mechanism passing through the center of the guide frame (601) and rotatably connected thereto. The three are coaxially arranged. The guide frame (601) is fixedly connected to an upper bracket (604) at both ends. The top of the upper bracket (604) is fixedly connected to an elastic coupling seat (8). The bottom of the guide frame (601) is provided with a rectangular guide groove (605). A roller (606) is embedded in the guide groove (605). A high-frequency reset spring (607) is also provided between the roller (606) and the guide groove (605). The excitation mechanism transmits impact energy directly to the outer roller (602) through the roller (606).
6. The steel structure component welding deformation correction device according to claim 5, characterized in that, The excitation mechanism includes an excitation spindle (603), with both ends of the excitation spindle (603) passing through and rotatably connected to both ends of the guide frame (601), and one end of the spindle (603) is fixedly connected to a motor (609). A cam (608) is fixedly connected to the outer wall of the excitation spindle (603). Under the action of the high-frequency return spring (607), the outer circumference of the roller (606) is in contact with the outer circumference of the cam (608), and the roller (606) moves back and forth in the guide groove (605) to apply pulse force in a direction perpendicular to the surface of the flange.
7. The steel structure component welding deformation correction device according to claim 5, characterized in that, An external gear ring (610) is fixedly connected to the outer wall of one end of the outer roller (602). A gear (611) is meshed with the tooth end of the external gear ring (610). A motor (612) is fixedly connected to the center of the gear (611). The outer wall of the motor (612) is fixedly connected to the outer wall of the upper bracket (604).
8. The steel structure component welding deformation correction device according to claim 1, characterized in that, The lower support assembly (4) includes a lower bracket (401), which is fixedly connected to the lifting end of the synchronous lifting frame (3). A support frame is slidably connected inside the lower bracket (401), and a screw mechanism is provided between the two. A lower support roller group (402) is fixedly connected to one side of the two support frames. The screw mechanism drives the support frame to move on the lower bracket (401), so that the lower support roller group (402) is close to or close to the steel structure component.