A mobile welding device for the base of angle steel towers

Abstract

This invention relates to the field of welding equipment technology, specifically to a mobile welding device for angle steel tower feet, comprising: a welding platform; a primary clamping chuck for the tower foot, rotatably mounted on the welding platform for supporting and clamping the angle steel tower foot blank; and a secondary clamping welding workpiece for the tower foot, positioned above the primary clamping chuck. The secondary clamping welding workpiece includes a support portion capable of vertical movement and multiple first clamping heads disposed on the support portion, each first clamping head corresponding to a vertical weld position on the angle steel tower foot blank. By providing multiple clamping heads, this application can provide circumferential clamping for the angle steel tower foot blank, making the clamping more stable. Combined with a robotic arm driven by a second hydraulic cylinder and a first pneumatic cylinder, the originally manually controlled and highly unstable vertical weld process is transformed into a more stable, automated mechanical welding operation, significantly reducing the operational difficulty.

Description

Technical Field

[0001] This invention relates to the field of welding equipment technology, and in particular to a special welding device for the legs of a mobile angle steel tower. Background Technology

[0002] Angle steel towers are crucial infrastructure in fields such as power transmission and communication broadcasting. The tower legs, as key components connecting the tower body to the foundation, directly affect the stability of the entire tower. Angle steel tower legs are typically welded together from a horizontal steel plate at the bottom and multiple vertically arranged steel plates above. Due to the large thickness of the tower leg components and the numerous and concentrated welds, significant welding stress and heat accumulation occur during the welding process.

[0003] In existing tower foot welding processes, horizontal steel plates are typically arranged with multiple vertical steel plates to form an angle steel tower foot blank. Then, the transverse welds between the horizontal and vertical steel plates, as well as the vertical welds between the vertical steel plates, are welded one by one. Simple positioning clamps are used for fixation throughout the welding process. Generally, because angle steel tower feet are relatively large, the welding of transverse welds is relatively convenient. However, the vertical welds are more difficult to weld due to the instability of manual clamping. Furthermore, due to the thermal cycle of welding, the steel plates undergo significant thermal expansion. Unstable manual clamping can lead to uneven gaps or misalignment, and the electric arc cannot stably heat the steel plates. If the clamping rigidity is too high, internal stress cannot be released, causing macroscopic structural distortion. If the clamping constraint is insufficient, the steel plates are prone to deformation after heating, leading to increased weld gaps and defects such as burn-through, lack of fusion, or poor weld formation, greatly weakening the connection strength between the steel plates. Uneven weld width and height, and even appearance defects such as undercut and weld beads, may also occur. Summary of the Invention

[0004] The main objective of this invention is to provide a special welding device for the legs of a mobile angle steel tower, in order to solve the problems raised in related technologies.

[0005] To achieve the above objectives, the present invention provides a special welding device for mobile angle steel tower legs, comprising:

[0006] Welding platform;

[0007] The tower foot primary clamping chuck is rotatably mounted on the welding platform to support and clamp the angle steel tower foot blank;

[0008] The secondary clamping and welding workpiece of the tower foot is set above the primary clamping chuck of the tower foot. The secondary clamping and welding workpiece of the tower foot includes a support part that can move in the vertical direction and a plurality of first clamping heads set on the support part. The plurality of first clamping heads correspond to the vertical weld positions of the angle steel tower foot blank. The first clamping head includes two side clamping plates and a central top plate located between the two side clamping plates. A second disc spring is connected between the side clamping plates and the central top plate for lateral flexible clamping of the vertical steel plate.

[0009] The welding actuator includes a robotic arm capable of moving in both vertical and horizontal directions. The end of the robotic arm is equipped with a welding head and a second clamping head. The second clamping head is located above the welding head and moves synchronously with the welding head. The second clamping head and a plurality of first clamping heads together provide circumferential clamping for both sides of the weld seam of the angle steel tower foot blank.

[0010] Furthermore, the secondary clamping assembly for the tower feet also includes a welding workpiece mounting bracket fixed to the welding platform, on which a first hydraulic cylinder is mounted.

[0011] Furthermore, the support part is a support ring, and the piston rod of the first hydraulic cylinder is connected to the support ring to drive the entire support ring to move vertically up and down.

[0012] Furthermore, the support ring is provided with a plurality of first clamping head support plates, and a second cylinder is installed on each first clamping head support plate. The first clamping head and the piston rod of the second cylinder are elastically connected by a first disc spring to provide elastic clamping pressure.

[0013] Furthermore, the side clamp is movably connected to the end of the central top plate, and the connection between the side clamp and the central top plate is arc-shaped.

[0014] Furthermore, the welding actuator also includes a top support beam installed on the top of the welding workpiece mounting bracket. A second hydraulic cylinder is installed on the top support beam. The piston rod of the second hydraulic cylinder is connected to a robotic arm mounting bracket. A first cylinder is provided on the robotic arm mounting bracket. The first cylinder drives the robotic arm to move horizontally.

[0015] Furthermore, the second clamping head also includes two side clamps and a central top plate located between the two side clamps, with a flexible spring connecting the side clamps and the central top plate.

[0016] Furthermore, the second clamping head is also equipped with a pressure feedback system, which includes a pressure sensor disposed on the surface of the side clamping plate, an external air pump, and a control terminal; the control terminal controls the external air pump to perform air inflation and deflation operations on the flexible spring according to the pressure fluctuation signal fed back by the pressure sensor, thereby dynamically adjusting the squeezing force of the side clamping plate on both sides of the weld.

[0017] Furthermore, a drive motor is connected below the primary clamping chuck of the tower foot to drive the angle steel tower foot blank to rotate to change the welding position, and the support ring is directly opposite the primary clamping chuck of the tower foot.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. This application provides circumferential clamping for the angle steel tower foot blank by setting multiple clamping heads, making the clamping more stable. Combined with the robotic arm driven by the second hydraulic cylinder and the first air cylinder, the original manual control-dependent and highly unstable vertical weld welding process is transformed into a more stable mechanical automated welding operation, which greatly reduces the difficulty of operation.

[0020] 2. This application provides an elastic clamping mechanism in the first clamping head, which allows the steel plate to have a small amount of deformation space when it is heated and expanded. This avoids the generation of huge residual stress inside the workpiece caused by rigid clamping and fixing, thereby preventing the overall macroscopic torsion deformation of the finished tower foot and effectively solving defects such as weld burn-through, lack of fusion or poor weld formation.

[0021] 3. This application introduces a pressure feedback system composed of a pressure sensor and a gas spring. This system can sense the pressure fluctuations generated by the welding thermal cycle on the steel plate in real time and compensate for the pressure by filling and evacuating the air with an air pump. This dynamic adjustment solves the appearance quality problems such as inconsistent weld width, uneven height, and poor forming, and ensures the connection strength between steel plates. Therefore, this invention can achieve rapid welding of vertical welds while ensuring the welding quality and welding strength between steel plates. Attached Figure Description

[0022] Figure 1 This is one of the overall schematic diagrams of the present invention;

[0023] Figure 2 This is a second overall schematic diagram of the present invention;

[0024] Figure 3 This is a schematic diagram of the secondary clamping and welding workpiece structure of the tower foot according to the present invention;

[0025] Figure 4 This is a schematic diagram of the first clamping head structure of the present invention;

[0026] Figure 5This is a top view of the first clamping head of the present invention.

[0027] Illustration:

[0028] 1. Welding platform; 2. Primary clamping chuck at the tower foot; 3. Welding workpiece mounting bracket; 4. Secondary clamping chuck at the tower foot; 41. Welding head; 42. Second clamping head; 45. Robotic arm; 46. Support ring; 412. Second cylinder; 413. First clamping head support plate; 414. First clamping head; 415. First disc spring; 418. Side clamping plate; 419. Central top plate; 420. Second disc spring; 5. First hydraulic cylinder; 6. Robotic arm mounting bracket; 7. Top support beam; 8. Second hydraulic cylinder; 9. First cylinder. Detailed Implementation

[0029] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0030] Please see Figures 1 to 5 This embodiment provides a special welding device for the legs of a mobile angle steel tower, the structure of which is as follows: Figure 1 As shown, the system includes a welding platform 1 fixed to the ground. A primary clamping chuck 2 for the tower legs is installed on the welding platform 1. A drive motor (installed inside the welding platform 1, not shown in the figure) is connected below the primary clamping chuck 2. The drive motor can drive the primary clamping chuck 2 to rotate at an angle. The angle steel tower leg blank is clamped and fixed on the primary clamping chuck 2 and rotates synchronously with it to change the welding position.

[0031] To facilitate the movement of the entire welding equipment, rollers can be installed under the welding platform 1.

[0032] The angle steel tower foot blank in this invention refers to the initial finished product formed by manually welding the transverse weld between the horizontal steel plate and the vertical steel plate using welding equipment.

[0033] like Figure 1 and Figure 2 As shown, two symmetrically arranged welding workpiece mounting brackets 3 are also fixedly installed on the welding platform 1. Each welding workpiece mounting bracket 3 has two first hydraulic cylinders 5 fixedly installed on it. Below the welding workpiece mounting bracket 3, a secondary clamping tower foot 4 is provided, which is connected to the welding workpiece mounting bracket 3 via the piston rod of the first hydraulic cylinder 5. The first hydraulic cylinder 5 drives the secondary clamping tower foot 4 to vertically lift and lower the entire assembly. To ensure centering accuracy, the center line of the secondary clamping tower foot 4 coincides with the rotation center line of the primary clamping tower foot chuck 2.

[0034] A top support beam 7 is fixedly installed on top of the two welding workpiece mounting brackets 3, and a second hydraulic cylinder 8 is mounted on the top support beam 7. A robotic arm mounting bracket 6 is also provided below the two welding workpiece mounting brackets 3. The piston rod of the second hydraulic cylinder 8 passes through the top support beam 7 and is fixedly connected to the robotic arm mounting bracket 6. Driven by the second hydraulic cylinder 8, the robotic arm mounting bracket 6 and the robotic arm 45 it carries can move up and down.

[0035] The specific structure of the secondary clamping welding workpiece 4 at the tower foot is as follows: It includes a support ring 46, and the piston rod end of the first hydraulic cylinder 5 is fixed to the support ring 46. Multiple sets of first clamping head support plates 413 are fixedly installed on the support ring 46. These multiple sets of first clamping head support plates 413 are arranged at specific angles to each other in the horizontal plane to correspond to the layout of the tower foot steel plates. Each first clamping head support plate 413 is equipped with a second cylinder 412 and has a first clamping head 414 slidably mounted on it. The first clamping head 414 is connected to the piston rod of the second cylinder 412 via a first disc spring 415, which serves as a preliminary buffer and constant pressure transmission mechanism.

[0036] Furthermore, the first clamping head 414 includes two side clamping plates 418 and a central top plate 419 located between the two side clamping plates 418. The ends of the side clamping plates 418 and the central top plate 419 are movably connected, and a second disc spring 420 is connected between them. The second disc spring 420 provides a lateral elastic clamping force to the side clamping plates 418. This elastic constraint allows the workpiece to expand slightly outward due to thermal expansion, thereby preventing distortion caused by stress concentration. The junction of the side clamping plates 418 and the central top plate 419 forms a smooth arc-shaped end. This design ensures that the first clamping head 414 can slide smoothly on the steel plate surface without jamming as it moves downward with the support ring 46.

[0037] A slide rail is fixedly mounted on the robotic arm mounting bracket 6, and a matching slider is fixedly mounted on the robotic arm 45. A first cylinder 9 is mounted on the robotic arm mounting bracket 6, and the end of its piston rod is connected to the robotic arm 45 to drive the robotic arm 45 to move horizontally along the slide rail. A welding head 41 and a second gripping head 42 are fixedly mounted on the end of the robotic arm 45, and the welding head 41 is located directly below the second gripping head 42.

[0038] The mechanical structure of the second clamping head 42 is basically the same as that of the first clamping head 414, also including two side clamping plates 418 and a central top plate 419. However, the side clamping plates 418 and the central top plate 419 are connected by a flexible spring. In this embodiment, the flexible spring can preferably be a gas spring. A pressure sensor is provided on the surface of the side clamping plates 418 of the second clamping head 42, and the sensor is electrically connected to an external control terminal. The control terminal monitors the real-time pressure signal fed back by the pressure sensor and controls the external air pump to inflate or depress the gas spring, thereby dynamically adjusting the extrusion pressure of the side clamping plates 418 on the steel plate surfaces on both sides of the weld, and compensating for the variable force generated during the welding thermal cycle.

[0039] The working principle and operation procedure of this device are as follows:

[0040] First, place the horizontal steel plate and multiple vertical steel plates on the primary clamping chuck 2 of the tower foot, and weld the transverse weld between the horizontal and vertical steel plates using welding equipment to form the angle steel tower foot blank.

[0041] The horizontal steel plate is clamped and fixed using the primary clamping chuck 2 of the tower foot. Due to the structural characteristics of the primary clamping chuck 2, its multiple clamping claws can automatically move towards the center of the primary clamping chuck 2 and clamp the angle steel tower foot blank. At this time, the angle steel tower foot blank is located at the center of the primary clamping chuck 2, and the secondary clamping welding workpiece 4 is located directly above the angle steel tower foot. At this time, the secondary clamping welding workpiece 4 and the angle steel tower foot blank are facing each other, and the vertical weld formed between the vertical steel plates is welded. The specific welding process is as follows:

[0042] The three sets of second cylinders 412 are activated to push the three first clamping heads 414 to press against the steel plates at the three weld seam positions respectively. At the same time, the first cylinder 9 is activated to drive the robotic arm 45 to move, so that the welding head 41 and the second clamping head 42 are aligned with the fourth weld seam. At this time, all the side clamping plates 418 are in close contact with the surface of the vertical steel plate.

[0043] At the start of welding, the first hydraulic cylinder 5 and the second hydraulic cylinder 8 are activated synchronously, driving the support ring 46 and the robotic arm 45 to move downwards at a uniform speed. The welding head 41 continuously welds the weld seam during this downward movement. Simultaneously, the second clamping head 42 moves synchronously with the welding head. Pressure sensors monitor the pressure changes of the plate material around the weld seam in real time, and the control terminal dynamically adjusts the gas spring pressure to ensure optimal clamping force is maintained in the heat-affected zone. This prevents gaps between the steel plates while allowing for slight thermal expansion displacement, achieving a more ideal anti-deformation effect.

[0044] After completing one weld, each clamping head retracts, and the drive motor rotates the primary clamping chuck 2 of the tower foot by a certain angle. The above steps are repeated until all four welds are completed.

[0045] In the above process, by setting multiple clamping heads, the angle steel tower foot blank can be provided with circumferential clamping, making the clamping more stable. Combined with the mechanical arm 45 driven by the second hydraulic cylinder 8 and the first air cylinder 9, the original vertical weld welding process, which was originally dependent on manual control and extremely unstable, is transformed into a more stable mechanical automated welding operation, which greatly reduces the difficulty of operation.

[0046] By setting up an elastic clamping mechanism composed of the first disc spring 415 and the second disc spring 420 in the first clamping head 414, the huge residual stress inside the workpiece caused by rigid clamping and fixing is avoided, thereby preventing the overall macroscopic torsion deformation of the finished tower foot and effectively solving defects such as weld burn-through, lack of fusion or poor weld formation.

[0047] By introducing a pressure feedback system composed of a pressure sensor and a gas spring, the system can sense the pressure fluctuations generated by the welding thermal cycle on the steel plate in real time, and compensate for the pressure by filling and evacuating the air with an air pump. This dynamic adjustment solves the appearance quality problems such as inconsistent weld width, uneven height, and poor forming, and ensures the connection strength between steel plates.

[0048] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A special welding device for the legs of a mobile angle steel tower, characterized in that, include: Welding platform (1); The tower foot primary clamping chuck (2) is rotatably mounted on the welding platform (1) and is used to support and clamp the angle steel tower foot blank; The secondary clamping welding workpiece (4) of the tower foot is set above the primary clamping chuck (2) of the tower foot. The secondary clamping welding workpiece (4) of the tower foot includes a support part that can move in the vertical direction and a plurality of first clamping heads (414) set on the support part. The plurality of first clamping heads (414) correspond to the vertical weld position of the angle steel tower foot blank. The first clamping head (414) includes two side clamping plates (418) and a central top plate (419) located between the two side clamping plates (418). A second disc spring (420) is connected between the side clamping plates (418) and the central top plate (419) for lateral flexible clamping of the vertical steel plate. The welding actuator includes a robotic arm (45) capable of moving in both vertical and horizontal directions. The end of the robotic arm (45) is equipped with a welding head (41) and a second clamping head (42). The second clamping head (42) is located above the welding head (41) and moves synchronously with the welding head (41). The second clamping head (42) and a plurality of first clamping heads (414) together provide circumferential clamping for both sides of the weld seam of the angle steel tower foot blank.

2. The mobile angle steel tower foot welding device according to claim 1, characterized in that: It also includes a welding workpiece mounting bracket (3) fixed on the welding platform (1), on which a first hydraulic cylinder (5) is mounted.

3. The mobile angle steel tower foot welding device according to claim 2, characterized in that: The support part is a support ring (46), and the piston rod of the first hydraulic cylinder (5) is connected to the support ring (46) to drive the support ring (46) to move vertically as a whole.

4. The mobile angle steel tower foot welding device according to claim 3, characterized in that: The support ring (46) is provided with a plurality of first clamping head support plates (413), and a second cylinder (412) is installed on each first clamping head support plate (413). The first clamping head (414) and the piston rod of the second cylinder (412) are elastically connected by a first disc spring (415) to provide elastic clamping pressure.

5. The mobile angle steel tower foot welding device according to claim 1, characterized in that: The side clamp (418) is movably connected to the end of the central top plate (419), and the connection between the side clamp (418) and the central top plate (419) is arc-shaped.

6. The mobile angle steel tower foot welding device according to claim 2, characterized in that: The welding actuator also includes a top support beam (7) installed on the top of the welding workpiece mounting bracket (3), a second hydraulic cylinder (8) is installed on the top support beam (7), the piston rod of the second hydraulic cylinder (8) is connected to the robotic arm mounting bracket (6), the robotic arm mounting bracket (6) is provided with a first cylinder (9), the first cylinder (9) drives the robotic arm (45) to move in the horizontal direction.

7. The mobile angle steel tower foot welding device according to claim 1, characterized in that: The second clamping head (42) also includes two side clamps (418) and a central top plate (419) located between the two side clamps (418), with a flexible spring connecting the side clamps (418) and the central top plate (419).

8. A special welding device for mobile angle steel tower legs according to claim 7, characterized in that: The second clamping head (42) is also provided with a pressure feedback system, which includes a pressure sensor, an external air pump and a control terminal disposed on the surface of the side clamping plate (418); the control terminal controls the external air pump to perform air filling and evacuation operations on the flexible spring according to the pressure fluctuation signal fed back by the pressure sensor, and dynamically adjusts the squeezing force of the side clamping plate (418) on both sides of the weld.

9. A special welding device for mobile angle steel tower legs according to claim 3, characterized in that: A drive motor is connected below the primary clamping chuck (2) of the tower foot, which is used to drive the angle steel tower foot blank to rotate to change the welding position, and the support ring (46) is directly opposite the primary clamping chuck (2) of the tower foot.

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