Integral type three-unit box girder positioning net welding machining equipment and system

Abstract

The invention relates to the technical field of prefabricated box girders, in particular to integrated three-unit box girder positioning net welding machining equipment and system.The machining equipment comprises a machining table and three box girder positioning net welding devices arranged around the machining table, and the machining table comprises a bottom plate table part and two web plate table parts; the bottom plate table part is used for placing components forming bottom plate meshes, the web table parts are used for placing components forming web meshes, and the three box girder positioning net welding devices are arranged around the machining table and correspond to the bottom plate table part and the two web table parts correspondingly; the box girder positioning net welding device comprises a base, a moving mechanism and a welding mechanism, the moving mechanism is used for driving the welding mechanism to move transversely and longitudinally relative to the base so that the welding mechanism can move to different positions of the machining table, and the welding mechanism is used for welding components placed on the machining table. The positioning net with the bottom plate net piece and the web plate net piece can be produced at a time, the production efficiency can be improved, and the labor cost can be reduced.

Description

Technical Field

[0001] This invention relates to the field of precast box girder technology, and in particular to an integral three-unit box girder positioning mesh welding processing equipment and system. Background Technology

[0002] During the prefabrication of box girders, positioning mesh needs to be pre-welded. This positioning mesh, often simply called positioning net, is a specialized welded steel mesh used to precisely position and fix the prestressed steel strands or reinforcing bars (corrugated pipes) during the prefabrication of concrete box girders. Depending on the location of the corresponding box girder, the positioning mesh can be divided into a bottom plate mesh and two web plates. The bottom plate mesh corresponds to the bottom plate of the box girder, and the web plates correspond to the web plates. Currently, there are two methods for processing positioning mesh in beam yard production: one is entirely manual welding; the other is to first weld the bottom plate mesh and web plates separately using a welding machine, and then combine one bottom plate mesh and two web plates to form an integral positioning mesh. This combination welding is usually done manually.

[0003] In beam yards, positioning mesh is usually produced in large quantities. The two processing methods mentioned above are inefficient and have high labor costs, making it difficult to meet the needs of cost reduction and efficiency improvement. Therefore, there is an urgent need for a positioning mesh processing equipment that can further improve processing efficiency and reduce labor costs. Summary of the Invention

[0004] This invention provides an integrated three-unit box girder positioning mesh welding and processing equipment and system, which aims to improve the processing efficiency of positioning mesh and reduce labor costs to at least a certain extent.

[0005] In a first aspect, the present invention provides an integrated three-unit box girder positioning mesh welding processing equipment, comprising a processing table and three box girder positioning mesh welding devices arranged around the processing table, wherein the processing table includes a base plate platform and two web plate platforms, the base plate platform being used to place components constituting the base plate mesh, and the web plate platforms being used to place components constituting the web plate mesh, and the three box girder positioning mesh welding devices being arranged around the processing table and respectively corresponding to the base plate platform and the two web plate platforms; each box girder positioning mesh welding device includes a base, a moving mechanism, and a welding mechanism, wherein:

[0006] The moving mechanism is used to drive the welding mechanism to move along the processing table. The moving mechanism includes a longitudinal moving component and a transverse moving component. The longitudinal moving component is used to drive the welding mechanism to move longitudinally relative to the base, and the transverse moving component is used to drive the welding mechanism to move laterally relative to the base. The welding mechanism includes an upper welding assembly and a lower welding assembly arranged vertically at intervals. The upper welding assembly is provided with a first linear module and a first resistance welding torch, and the lower welding assembly is provided with a second linear module and a second resistance welding torch. The first resistance welding torch and the second resistance welding torch are opposite to each other. The first linear module is used to drive the first resistance welding torch to move toward or away from the second resistance welding torch, and the second linear module is used to drive the second resistance welding torch to move toward or away from the first resistance welding torch, so that the first resistance welding torch and the second resistance welding torch move toward and in opposite directions.

[0007] In some embodiments, the longitudinal movement assembly includes a longitudinal track, a longitudinal linear module, and a first slide plate, the longitudinal track being disposed on the base, and the longitudinal linear module being used to drive the first slide plate to move along the longitudinal track.

[0008] In some embodiments, the lateral movement assembly includes a lateral track, a lateral linear module, and a second slide plate. The lateral track is disposed on the first slide plate, and the lateral linear module is used to drive the second slide plate to move along the lateral track. The welding mechanism is mounted on the second slide plate.

[0009] In some embodiments, the first linear module is an electric telescopic cylinder or a ball screw module.

[0010] In some embodiments, the second linear module is an electric telescopic cylinder or a ball screw module.

[0011] In some embodiments, the longitudinal linear module is an electric telescopic cylinder or a ball screw module.

[0012] In some embodiments, the transverse linear module is an electric telescopic cylinder or a ball screw module.

[0013] In some embodiments, the processing table has a hollow structure, and the first resistance welding gun and the second resistance welding gun can be moved to the hollow position of the processing table.

[0014] In some embodiments, a central controller is also included, and the first linear module, the second linear module, the longitudinal linear module, the transverse linear module, the first resistance welding gun, and the second resistance welding gun in the three box girder positioning mesh welding devices are all communicatively connected to the central controller.

[0015] In some embodiments, the welding mechanism includes a vertical support structure and a first support arm and a second support arm protruding from the side of the vertical support structure, wherein the first linear module is mounted on the first support arm and the first resistance welding gun is mounted on the first linear module; the second linear module is mounted on the second support arm and the second resistance welding gun is mounted on the second linear module.

[0016] In some embodiments, all three box girder positioning mesh welding devices are located outside the processing table, and the first support arm and the second support arm in each box girder positioning mesh welding device protrude from the side of the vertical support structure near the processing table, so that the first support arm and the second support arm can extend into the vertical space of the processing table.

[0017] In some embodiments, at least two upper welding components are arranged side by side on the first support arm, and at least two lower welding components are arranged side by side on the second support arm, with the upper welding components and lower welding components being arranged in a one-to-one correspondence.

[0018] In some embodiments, the first support arm and the second support arm are arranged laterally along the box girder positioning mesh welding device.

[0019] In a second aspect, the present invention provides an integral three-unit box girder positioning mesh welding system, comprising a plurality of reinforcing bars and an integral three-unit box girder positioning mesh welding processing equipment as described above, wherein at least some of the reinforcing bars are arranged to cross and overlap each other on the processing table, and the box girder positioning mesh welding device is used to weld at least some of the intersection points.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows: The integrated three-unit box girder positioning mesh welding and processing equipment of this invention has three box girder positioning mesh welding devices corresponding to the bottom plate platform and two web plate platforms, respectively. In use, all components constituting the positioning mesh can be laid sequentially on the processing table. Then, the moving mechanism in the three box girder positioning mesh welding devices drives the welding mechanism to move along the processing table to weld each point that needs to be welded. This allows for the one-time production of positioning mesh with bottom plate mesh and web plate mesh. Compared to the existing technology of separately welding the bottom plate mesh and web plate mesh and then manually assembling them to form a complete positioning mesh, production efficiency is greatly improved, with a daily output reaching several... The system uses hundreds of large positioning mesh panels, requiring less manual intervention and reducing labor costs. Simultaneously, the welding mechanism is equipped with a first and second resistance welding gun, employing resistance welding technology. This ensures welding quality while allowing all semi-finished components to be welded without needing to be moved during the process, simplifying the process. Furthermore, a moving mechanism drives the welding mechanism along the processing table. Welding is performed by keeping the components to be welded stationary relative to the ground while the welding mechanism moves relative to the ground. During welding, the processing table and its components remain stationary relative to the ground, maintaining stable relative positions and improving finished product quality. Attached Figure Description

[0021] Figure 1 This is a top view schematic diagram of the integrated three-unit box girder positioning mesh welding processing equipment described in an embodiment of the present invention; Figure 2 This is a schematic diagram of the integrated three-unit box girder positioning mesh welding and processing equipment described in an embodiment of the present invention; Figure 3 This is a schematic diagram of the upper welding assembly and the lower welding assembly described in an embodiment of the present invention.

[0022] Marked in the image: 1-Processing table; 11-Bottom plate platform; 12-Web plate platform; 2-Longitudinal translation component; 21-Longitudinal track; 22-First skateboard; 3- Lateral movement component; 31-Horizontal track; 32-Second skateboard; 4-Vertical support structure; 41-First support arm; 42 - Upper welding assembly; 421 - First linear module; 422 - First resistance welding torch; 43 - Second support arm; 44-Lower welding assembly; 441 - Second linear module; 442 - Second resistance welding torch; 5-Central controller; 6- Mold worktable. Detailed Implementation

[0023] The present invention will now be described in further detail with reference to specific embodiments. However, this should not be construed as limiting the scope of the present invention to the following embodiments; all technologies implemented based on the content of the present invention fall within the scope of the present invention.

[0024] Unless otherwise specified, the use of terms such as "upper," "lower," "left," "right," "center," "inner," and "outer" to indicate orientation or positional relationships in the description of specific embodiments of the present invention is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationship in which the product / equipment / device is typically placed during use. These terms are merely for the purpose of facilitating the description of the present invention or simplifying the description in specific embodiments, enabling those skilled in the art to quickly understand the solution, and do not indicate or imply that a particular device / component / element must have a specific orientation, or be constructed and operated in a specific positional relationship. Therefore, they should not be construed as limitations on the present invention.

[0025] Furthermore, the use of terms such as "horizontal," "vertical," "suspended," and "parallel" does not imply that the corresponding device / component / element must be absolutely horizontal, vertical, suspended, or parallel, but rather that it can be slightly tilted or have a deviation. For example, "horizontal" merely means that its direction is more horizontal relative to "vertical," not that the structure must be completely horizontal, but that it can be slightly tilted. Alternatively, it can be simplified to mean that the corresponding device / component / element, when set in a "horizontal," "vertical," "suspended," or "parallel" direction, can have an error / deviation of ±10% relative to the corresponding direction, more preferably within ±8%, more preferably within ±6%, more preferably within ±5%, and more preferably within ±4%. As long as the corresponding device / component / element is within the error / deviation range, it can still achieve its function in the present invention.

[0026] Furthermore, the use of terms such as "first," "second," and "third" in terminology is merely for distinguishing descriptions of identical or similar components and should not be interpreted as emphasizing or implying the relative importance of a particular component.

[0027] Furthermore, in the description of the embodiments of the present invention, "several", "more than", and "a number of" represent at least two. The number can be any number, such as 2, 3, 4, 5, 6, 7, 8, or 9, and can even exceed nine.

[0028] Furthermore, in the description of the technical solution of this invention, unless otherwise explicitly specified / limited / restricted, the terms "set up," "install," "connect," "link," "provided with," "laid out," and "arranged" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to common connection methods in the art, such as welding, riveting, bolting, and threaded connections. Such connections can be mechanical, electrical, or communication connections; they can be direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components.

[0029] Positioning mesh, often simply called positioning mesh, is a specialized welded steel mesh used in the precast concrete box girder manufacturing process to precisely position and fix the prestressed steel strands or reinforcing bars (corrugated pipes). Depending on the corresponding box girder position, the positioning mesh can be divided into a bottom plate mesh and two web plates. The bottom plate mesh corresponds to the bottom plate of the box girder, and the web plates correspond to the web plates. In beam yard production, the bottom plate mesh and web plates are typically welded separately by welding machines, and then one bottom plate mesh and two web plates are combined and welded together to form an integral positioning mesh. Currently, this combination welding is usually done manually, which suffers from low welding efficiency and difficulty in guaranteeing welding quality.

[0030] The present invention will now be described with reference to the accompanying drawings and specific embodiments: The first aspect of the present invention provides an integrated three-unit box girder positioning mesh welding and processing equipment, which can weld the box girder positioning mesh in one go, greatly improving production efficiency.

[0031] Specifically, in combination Figure 1 and Figure 2 The integrated three-unit box girder positioning mesh welding equipment includes a processing table 1 and three box girder positioning mesh welding devices arranged around the processing table 1. The processing table 1 includes a base plate 11 and two web plate 12. The base plate 11 is used to place several components that make up the base plate mesh, and the web plate 12 is used to place several components that make up the web plate mesh. The three box girder positioning mesh welding devices are arranged around the processing table 1 and correspond to the base plate 11 and the two web plate 12 respectively. The box girder positioning mesh welding device includes a base, a moving mechanism, and a welding mechanism. The moving mechanism is used to drive the welding mechanism to move horizontally and longitudinally relative to the base so that the welding mechanism moves to different positions on the processing table 1. The welding mechanism is used to weld the components placed on the processing table 1.

[0032] In use, all components that make up the positioning mesh can be laid sequentially on the processing table 1. Then, the moving mechanism in the three box girder positioning mesh welding devices drives the welding mechanism to move along the processing table 1 to weld each point that needs to be welded, thereby welding a complete positioning mesh in one go. During the welding process, the processing table 1 and the components on it are stationary relative to the ground, and the relative positions between the components can remain stable, which is conducive to improving the quality of the finished product. The complete positioning mesh can be welded in one go. Compared with the existing technology of welding the bottom plate mesh and the web plate mesh separately and then manually combining and welding them to form a complete positioning mesh, the production efficiency is greatly improved.

[0033] like Figure 1 and Figure 2 As shown, the processing table 1 is the basic support and positioning platform for the entire equipment. It can be constructed by welding steel structures to ensure sufficient rigidity and stability. The processing table 1 mainly includes a base plate 11 and two web plate 12. The two web plate 12 are located on both sides of the base plate 11. Both the base plate 11 and the web plate 12 are at a certain height above the ground and are roughly horizontal, used to place and position the components that make up the positioning mesh (also known as the components to be welded). Moreover, in order to adapt to the shape of the box girder positioning mesh, each web plate 12 is not perpendicular to the base plate 11, but forms an obtuse angle greater than 90 degrees (for example, according to common box girder designs, the angle can be 100°-120°). This angle simulates the actual angle between the web and the base plate in the box girder section, ensuring that the web plate mesh to be welded can be positioned and welded at the correct spatial angle.

[0034] In some embodiments, the processing table 1 has a hollow structure, and the first resistance welding gun 422 and the second resistance welding gun 442 can be moved to the hollow position of the processing table 1.

[0035] The table surface of the processing table 1 can be designed as a hollow grid or strip grid structure, forming a large number of hollow positions. The advantage of this design is that, on the one hand, it reduces the weight of the processing table 1, and on the other hand, and most importantly, it provides welding space for the upper and lower resistance welding guns of the welding mechanism, so that they can simultaneously contact the component to be welded from the upper and lower sides of the grid and complete the welding of the component to be welded without interfering with the solid table surface.

[0036] Combination Figure 1 Three box girder positioning mesh welding devices are arranged around the processing table 1. Specifically, one of the three box girder positioning mesh welding devices faces the bottom plate platform 11 and is mainly responsible for welding the components to be welded on the bottom plate platform 11. The other two box girder positioning mesh welding devices are respectively set on both sides of the bottom plate platform 11. These two box girder positioning mesh welding devices can face the web plate platform 12, or be perpendicular to the box girder positioning mesh welding device facing the bottom plate platform 11, or form other angles with the web plate platform 12. No limitation is imposed, as long as it can weld the weld points.

[0037] In this embodiment, the two box girder positioning mesh welding devices corresponding to the web plate platform 12 are perpendicular to the box girder positioning mesh welding device corresponding to the bottom plate platform 11. The three box girder positioning mesh welding devices form a semi-enclosed structure. The advantage of doing this is that it is easier to calibrate the starting position of the moving mechanism and also easier to calculate the amount of movement in different directions in the rectangular coordinate system based on the coordinates of each welding point, so as to achieve precise welding.

[0038] Depending on the width and height of the box girder, the dimensions of the bottom plate platform 11 and the web plate platform 12 can also be set differently. Among the three box girder positioning mesh welding devices, the dimensions of the box girder positioning mesh welding device corresponding to the bottom plate platform 11 and the box girder positioning mesh welding device corresponding to the web plate platform 12 can also be set differently. The specific dimensions can be adapted to actual needs, and the present invention does not limit them.

[0039] In some embodiments, the moving mechanism includes a longitudinal moving component 2 and a transverse moving component 3, both of which are mounted on a base. The longitudinal moving component 2 is used to drive the welding mechanism to move longitudinally relative to the base, and the transverse moving component 3 is used to drive the welding mechanism to move laterally relative to the base. Here, "lateral" and "longitudinal" refer to the direction relative to the base. That is, for different box girder positioning mesh welding devices, if the placement direction of their bases is inconsistent, then the moving directions of the longitudinal moving component 2 and the transverse moving component 3 in different box girder positioning mesh welding devices will also be inconsistent. For ease of description of this scheme, the two basic directions based on the processing table 1 are uniformly defined as the X-direction and the Y-direction. The X-direction and the Y-direction are perpendicular to each other and parallel to the horizontal plane.

[0040] In this embodiment, combined with Figure 1 The longitudinal direction of the box girder positioning mesh welding device corresponding to the bottom plate platform 11 is parallel to the X direction, and the transverse direction is parallel to the Y direction. The longitudinal direction of the box girder positioning mesh welding device corresponding to the web plate platform 12 is parallel to the Y direction, and the transverse direction is parallel to the X direction.

[0041] In one alternative implementation, combined with Figure 1 and Figure 2 The longitudinal movement component 2 includes a longitudinal track 21, a longitudinal linear module, and a first sliding plate 22. The longitudinal track 21 is mounted on a base, and the first sliding plate 22 is movably fitted onto the longitudinal track 21. The longitudinal linear module drives the first sliding plate 22 to move along the longitudinal track 21. Specifically, the longitudinal track 21 can be an upwardly protruding slide rail. The bottom of the first sliding plate 22 can be provided with a slider that can slide and engage with the slide rail. The slider has a downward-facing groove that surrounds the protruding part of the slide rail and can move along the slide rail. The longitudinal linear module provides a driving force for the movement of the first sliding plate 22 relative to the longitudinal track 21. This driving force can be bidirectional, meaning that the longitudinal linear module can drive the first sliding plate 22 to reciprocate along the longitudinal track 21. Of course, the longitudinal track 21 and the first sliding plate 22 can also be in other forms. For example, the track can be a cylindrical shaft, and the sliding plate can be a bushing or a semi-circular hole support that engages with it. This invention does not impose specific limitations.

[0042] In one alternative implementation, combined with Figure 1 and Figure 2The lateral movement component 3 includes a lateral track 31, a lateral linear module, and a second sliding plate 32. The lateral track 31 is disposed on a first sliding plate 22, and the second sliding plate 32 is movably fitted onto the lateral track 31. The lateral linear module is used to drive the second sliding plate 32 to move along the lateral track 31. Specifically, the lateral track 31 can be an upwardly protruding slide rail. The bottom of the second sliding plate 32 can be provided with a slider that can slide and engage with the slide rail. The slider has a downward-facing groove that surrounds the protruding part of the slide rail and can move along the slide rail. The lateral linear module is used to provide driving force for the movement of the second sliding plate 32 relative to the lateral track 31. This driving force can be bidirectional, that is, the lateral linear module can drive the second sliding plate 32 to reciprocate along the lateral track 31. Of course, the lateral track 31 and the second sliding plate 32 can also be in other forms. For example, the track can be a cylindrical shaft, and the sliding plate can be a bushing or a semi-circular hole support that engages with it. This invention does not impose specific limitations.

[0043] Based on the above implementation, the welding mechanism can be installed on the second slide plate 32, so that the welding mechanism can move laterally and longitudinally relative to the base under the drive of the longitudinal linear module and the transverse linear module, thereby welding different welding points on the processing table 1.

[0044] Optionally, the longitudinal linear module is an electric telescopic cylinder or a ball screw module, and the transverse linear module is an electric telescopic cylinder or a ball screw module.

[0045] Both electric telescopic cylinders and ball screw modules are devices that convert the rotary motion of a motor into linear motion. The difference lies in the length of the electric telescopic cylinder during operation. It typically has a closed structure, including an external cylinder and piston, and an internal rotating motor, lead screw, and lead screw nut. The lead screw nut is fitted onto the lead screw and its rotation is restricted by the cylinder. The piston is connected to the lead screw nut via a connector. The rotating motor drives the lead screw to rotate, which in turn drives the lead screw nut to move along the lead screw, thus pushing the piston to extend or retract relative to the cylinder. Electric telescopic cylinders can also be called electric push rods, electric cylinders, or linear actuators. In practical applications, taking the longitudinal movement component 2 as an example... An electric telescopic cylinder can be installed at one end of the longitudinal rail 21, and then the first slide plate 22 can be moved along the longitudinal rail 21 by telescopic drive. The length of the ball screw module remains constant, and it is usually an open structure. For example, it may include a linear guide, a rotary motor, a ball screw and a slide table. The slide table is sleeved on the ball screw and movably connected to the linear guide. The rotary motor can drive the screw to rotate, thereby driving the slide table to move along the linear guide. In practical applications, taking the longitudinal movement component 2 as an example: the linear guide can be installed parallel to one side of the longitudinal rail 21, and the slide table is fixedly connected to the first slide plate 22, thereby driving the first slide plate 22 to move along the longitudinal rail 21 through the slide table.

[0046] In some embodiments, combined with Figure 2 and Figure 3 The welding mechanism includes an upper welding assembly 42 and a lower welding assembly 44 arranged vertically at intervals. The upper welding assembly 42 is provided with a first linear module 421 and a first resistance welding gun 422, and the lower welding assembly 44 is provided with a second linear module 441 and a second resistance welding gun 442. The first resistance welding gun 422 and the second resistance welding gun 442 are opposite to each other. The first linear module 421 is used to drive the first resistance welding gun 422 to move toward or away from the second resistance welding gun 442, and the second linear module 441 is used to drive the second resistance welding gun 442 to move toward or away from the first resistance welding gun 422, so that the first resistance welding gun 422 and the second resistance welding gun 442 move toward and in opposite directions.

[0047] Furthermore, the first linear module 421 is used to drive the first resistance welding gun 422 to move toward and away from the second resistance welding gun 442, and the second linear module 441 is used to drive the second resistance welding gun 442 to move toward and away from the first resistance welding gun 422.

[0048] Resistance welding guns are tools used for resistance welding. Resistance welding refers to the process of applying pressure and current to a workpiece, using the heat generated by the current to locally melt the workpiece, and then welding two workpieces together under pressure. The first resistance welding gun 422 and the second resistance welding gun 442 are opposite each other, meaning that their gun heads are opposite each other, that is, the parts they are used for welding are opposite each other. Copper alloy electrodes can be installed on the parts used for welding to release a large current. The two resistance welding guns can form a set of welding electrodes. Driven by the first linear module 421 and the second linear module 441, the first resistance welding gun 422 and the second resistance welding gun 442 can move towards and away from each other. When moving towards each other, the distance between the first resistance welding gun 422 and the second resistance welding gun 442 decreases. When the distance is reduced to be equal to or slightly less than the thickness of the component to be welded, the first resistance welding gun 422 and the second resistance welding gun 442 can apply pressure to the component to be welded. At this time, resistance welding of the component to be welded can be achieved by applying current through the two resistance welding guns. When moving away from each other, the distance between the first resistance welding gun 422 and the second resistance welding gun 442 increases, and the first resistance welding gun 422 and the second resistance welding gun 442 separate from the component to be welded. There is a sufficiently large space between the first resistance welding gun 422 and the second resistance welding gun 442 so that they can move towards the component to be welded.

[0049] Optionally, the first linear module 421 is an electric telescopic cylinder or a ball screw module; the second linear module 441 is an electric telescopic cylinder or a ball screw module, and the specific structure of the electric telescopic cylinder or ball screw module is as described above; the motor in the electric telescopic cylinder or ball screw module can be a servo motor, which has higher precision and is beneficial to improving the quality of the finished product.

[0050] In one specific implementation scenario, the first resistance welding gun 422 moves vertically under the drive of the first linear module 421, and the second resistance welding gun 442 also moves vertically under the drive of the second linear module 441. The component to be welded consists of several steel bars placed horizontally on the processing table 1 to form a positioning mesh. The steel bars are arranged to intersect and overlap each other. The first resistance welding gun 422 and the second resistance welding gun 442 are used to perform resistance welding on the intersections (also called weld points). Driven by the moving mechanism, the first resistance welding gun 422 and the second resistance welding gun 442 can move from one intersection to another, thereby welding multiple intersections. Moreover, the box girder positioning mesh welding device can not only weld the intersections inside the corresponding bottom plate mesh or web mesh, but also weld the intersections at the junction of the bottom plate mesh and the web mesh, thereby completing the welding of the positioning mesh in one go and greatly improving processing efficiency.

[0051] It is understandable that the intersection points of the bottom plate mesh and the web mesh are not substantially different from the intersection points in other parts, and the welding methods are also the same. It is only necessary to pre-define the intersection points to be handled by each box girder positioning mesh welding device, and then the welding of each intersection point can be carried out simultaneously by the three box girder positioning mesh welding devices. Existing positioning mesh welding equipment achieves welding by moving the positioning mesh to the welding position, but can only complete the welding of a portion of the mesh at a time. Usually, the bottom plate mesh and the web mesh are welded separately, and then manually combined for welding, making it difficult to further improve processing efficiency. Moreover, the inertia of the positioning mesh when starting and stopping can easily cause relative displacement between components, making it difficult to guarantee the quality of the finished product. The integrated three-unit box girder positioning mesh welding processing equipment of the present invention adopts the method of welding in which the component to be welded is stationary relative to the ground and the welding mechanism moves relative to the ground. In use, multiple welding mechanisms can work simultaneously, which can not only improve processing efficiency, but also increase the coverage of welding, thereby processing a complete positioning mesh in one go. Moreover, since each component of the positioning mesh is stationary relative to the ground, the relative position between each component can remain stable, which is conducive to improving the quality of the finished product.

[0052] In some embodiments, combined with Figure 2 The welding mechanism includes a vertical support structure 4 and a first support arm 41 and a second support arm 43 protruding from the side of the vertical support structure 4. A first linear module 421 is mounted on the first support arm 41, and a first resistance welding gun 422 is mounted on the first linear module 421. A second linear module 441 is mounted on the second support arm 43, and a second resistance welding gun 442 is mounted on the second linear module 441.

[0053] Both support arms can be fixedly connected to the vertical support structure 4, and the distance between them remains constant. The fixed part of the first linear module 421 can be fixedly installed on the extended part of the first support arm 41, and the first resistance welding gun 422 is fixedly installed on the movable part of the first linear module 421, so that the first resistance welding gun 422 moves toward or away from the second resistance welding gun 442 by the movement of the movable part relative to the fixed part; the fixed part of the second linear module 441 can be fixedly installed on the extended part of the second support arm 43, and the second resistance welding gun 442 is fixedly installed on the movable part of the second linear module 441, so that the second resistance welding gun 442 moves toward or away from the first resistance welding gun 422 by the movement of the movable part relative to the fixed part; Figure 2 As shown, the first resistance welding gun 422 can be set vertically downwards, and the second resistance welding gun 442 can be set vertically upwards.

[0054] Both the first linear module 421 and the second linear module 441 can be electric telescopic cylinders or ball screw modules. If it is an electric telescopic cylinder, the fixed part can be a cylinder barrel and the moving part can be a piston, thereby driving the resistance welding gun to move by the extension and retraction of the piston relative to the cylinder barrel. If it is a ball screw module, the fixed part can be a linear guide rail or a part fixedly connected to the linear guide rail, and the moving part can be a slide or a part fixedly connected to the slide.

[0055] In some embodiments, the integrated three-unit box girder positioning mesh welding equipment is further equipped with a central controller 5. The first linear module 421, the second linear module 441, the longitudinal linear module, the transverse linear module, the first resistance welding gun 422, and the second resistance welding gun 442 in the three box girder positioning mesh welding devices are all communicatively connected to the central controller 5. Specifically, when the first linear module 421, the second linear module 441, the longitudinal linear module, and the transverse linear module are all electric telescopic cylinders or ball screw modules, their power source is a motor. Each motor can be connected to the central controller 5 through wires, thereby controlling the movement of each linear module through the central controller 5. Existing resistance welding guns are all equipped with control circuits and signal interfaces. The signal interfaces can be communicatively connected to the central controller 5 through signal lines, thereby controlling the opening and closing and working status of each resistance welding gun through the central controller 5.

[0056] The central controller 5 can be an industrial PLC. The power supply and control circuits of each linear module and resistance welding gun can be connected to the central controller 5. Operators can preset welding programs on the control panel of the central controller 5. The welding program can include parameters such as the coordinates of the welding points of each mesh, welding pressure, current, and time. The central controller 5 synchronously coordinates the actions of the three box girder positioning mesh welding devices, directing them to work synchronously, which greatly improves the processing efficiency of positioning mesh, meets the production needs of high-strength, high-precision, and large-volume positioning mesh, and achieves the effect of accelerating the construction progress and reducing the overall cost. Moreover, by coordinating and controlling the operation of each linear module and resistance welding gun through the central controller 5, workers can move away after placing the components to be welded. The welding process does not require workers to approach the welding area, which can reduce the health hazards of metal fumes and radiation to workers.

[0057] Optionally, each box girder positioning mesh welding device can be equipped with a separate unit controller, which can also be an industrial PLC. The unit controller is responsible for controlling the linear module and resistance welding gun in its corresponding box girder positioning mesh welding device, and the unit controller is equipped with an external communication interface for communication connection with the central controller 5. For example, in conjunction with... Figure 2 The vertical support structure 4 is the distribution box shell, which contains the various components that constitute the unit controller. Each unit can work in parallel or independently under the scheduling of the central controller 5.

[0058] In some embodiments, combined with Figure 1 and Figure 2 The three box girder positioning mesh welding devices are all located on the outside of the processing table 1. The first support arm 41 and the second support arm 43 in each box girder positioning mesh welding device are protruding and set on the side of the vertical support structure 4 close to the processing table 1, so that the first support arm 41 and the second support arm 43 can extend into the vertical space of the processing table 1, that is, extend into the top and / or bottom of the processing table 1. The two support arms can be set in the transverse direction of the box girder positioning mesh welding device, so that the length of the welding mechanism extending into the processing table 1 can be controlled by the transverse component 3, and the movement of the welding mechanism in the two-dimensional coordinate system can be controlled by the cooperation of the longitudinal component 2 and the transverse component 3.

[0059] In some embodiments, to further improve welding efficiency, at least two upper welding components 42 are arranged in parallel on the first support arm 41, and at least two lower welding components 44 are arranged in parallel on the second support arm 43. The upper welding components 42 and the lower welding components 44 are arranged in a one-to-one correspondence to form multiple sets of welding electrodes, such as two sets, three sets, etc. The spacing between each set of welding electrodes remains constant, but the contact between them and the component to be welded can be controlled by controlling whether the linear module of each set of welding electrodes extends or retracts. The positioning mesh is usually mass-produced, and the position of the welding points on it is usually fixed, that is, the spacing between the welding points is fixed. By setting multiple sets of welding electrodes, multiple welding points in the horizontal direction can be welded at the same time each time it moves into place, which greatly improves the processing efficiency.

[0060] In some embodiments, combined with Figure 1 and Figure 2 The area enclosed by the processing table 1 is provided with a mold worktable 6. The surface of the mold worktable 6 is lower than the surface of the processing table 1. The mold worktable 6 can be used to place components to be welded or for workers to stand on to arrange components to be welded on the processing table 1.

[0061] This equipment can produce the positioning mesh for the bottom slab and web reinforcement in one go, which is faster and more convenient than the traditional separate production and reassembly method. It also boasts high production efficiency, with three units operating in parallel, achieving a daily output of hundreds of large positioning meshes. High precision is ensured by using servo motors and precise positioning mechanisms, guaranteeing extremely small reinforcement spacing errors, typically controlled within ±1mm, fully meeting the stringent requirements of bridge engineering. Simultaneously, mature resistance welding technology and high-quality electrical and pneumatic components ensure the equipment can withstand 24-hour continuous high-intensity operation. This integrated three-unit box girder positioning mesh welding and processing equipment can solve the production needs of high-strength, high-precision, and large-volume reinforcement cages in large-scale engineering construction, making it a key tool for improving the quality of precast components, accelerating construction progress, and reducing overall costs.

[0062] A second aspect of the present invention provides an integral three-unit box girder positioning mesh welding system. This system includes not only the integral three-unit box girder positioning mesh welding processing equipment as described above, but also all the components to be welded required to form the positioning mesh, namely, steel bars of various specifications [in some working conditions, steel plates may also be used]. The components to be welded are arranged to cross and overlap each other, and some of the intersections are welding points, that is, welding points, which are welded by the box girder positioning mesh welding device to form a complete positioning mesh.

[0063] To maintain the stability of the position of each component to be welded during the welding process, several limiting grooves can be set on the processing table 1. Each component to be welded is partially embedded in the limiting groove, thereby reducing the probability of them sliding along the surface of the processing table 1. Alternatively, workers can use steel wire to tie and fix each component to be welded.

[0064] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated three-unit box girder positioning mesh welding and processing equipment, characterized in that, The system includes a processing table (1) and three box girder positioning mesh welding devices arranged around the processing table (1). The processing table (1) includes a base plate (11) and two web plate sections (12). The base plate (11) is used to place components that make up the base plate mesh, and the web plate sections (12) are used to place components that make up the web plate mesh. The three box girder positioning mesh welding devices are arranged around the processing table (1) and correspond to the base plate (11) and the two web plate sections (12), respectively. Each box girder positioning mesh welding device includes a base, a moving mechanism, and a welding mechanism. The moving mechanism is used to drive the welding mechanism to move along the processing table (1). The moving mechanism includes a longitudinal moving component (2) and a transverse moving component (3). The longitudinal moving component (2) is used to drive the welding mechanism to move longitudinally relative to the base, and the transverse moving component (3) is used to drive the welding mechanism to move laterally relative to the base. The welding mechanism includes an upper welding assembly (42) and a lower welding assembly (44) arranged vertically at intervals. The upper welding assembly (42) is provided with a first linear module (421) and a first resistance welding torch (422). The lower welding assembly (44) is provided with a second linear module (441) and a second resistance welding torch (442). The first resistance welding torch (422) and the second resistance welding torch (442) are opposite to each other. The first linear module (421) is used to drive the first resistance welding torch (422) to move toward or away from the second resistance welding torch (442). The second linear module (441) is used to drive the second resistance welding torch (442) to move toward or away from the first resistance welding torch (422), so that the first resistance welding torch (422) and the second resistance welding torch (442) move toward and away from each other.

2. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 1, characterized in that, The longitudinal movement component (2) includes a longitudinal track (21), a longitudinal straight module and a first slide plate (22). The longitudinal track (21) is disposed on the base, and the longitudinal straight module is used to drive the first slide plate (22) to move along the longitudinal track (21). The lateral movement component (3) includes a lateral track (31), a lateral straight module, and a second slide plate (32). The lateral track (31) is disposed on the first slide plate (22), and the lateral straight module is used to drive the second slide plate (32) to move along the lateral track (31). The welding mechanism is mounted on the second slide plate (32).

3. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 2, characterized in that: The first linear module (421) is an electric telescopic cylinder or a ball screw module; The second linear module (441) is an electric telescopic cylinder or a ball screw module; The longitudinal linear module is an electric telescopic cylinder or a ball screw module. The horizontal linear module is an electric telescopic cylinder or a ball screw module.

4. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 1, characterized in that, The processing table (1) has a hollow structure, and the first resistance welding gun (422) and the second resistance welding gun (442) can be moved to the hollow position of the processing table (1).

5. The integrated three-unit box girder positioning mesh welding and processing equipment according to any one of claims 1-4, characterized in that, It also includes a central controller (5), and the first linear module (421), the second linear module (441), the longitudinal linear module, the transverse linear module, the first resistance welding gun (422), and the second resistance welding gun (442) in the three box girder positioning mesh welding devices are all connected to the central controller (5).

6. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 5, characterized in that, The welding mechanism includes a vertical support structure (4) and a first support arm (41) and a second support arm (43) protruding from the side of the vertical support structure (4). The first linear module (421) is mounted on the first support arm (41), and the first resistance welding gun (422) is mounted on the first linear module (421). The second linear module (441) is mounted on the second support arm (43), and the second resistance welding gun (442) is mounted on the second linear module (441).

7. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 6, characterized in that, All three box girder positioning mesh welding devices are located on the outside of the processing table (1). The first support arm (41) and the second support arm (43) in each box girder positioning mesh welding device protrude from the vertical support structure (4) on the side close to the processing table (1) so that the first support arm (41) and the second support arm (43) can extend into the vertical space of the processing table (1).

8. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 6, characterized in that, At least two upper welding components (42) are arranged side by side on the first support arm (41), and at least two lower welding components (44) are arranged side by side on the second support arm (43). The upper welding components (42) and the lower welding components (44) are arranged in a one-to-one correspondence.

9. The integrated three-unit box girder positioning mesh welding and processing equipment according to claim 6, characterized in that, The first support arm (41) and the second support arm (43) are arranged laterally along the box girder positioning mesh welding device.

10. An integrated three-unit box girder positioning mesh welding system, characterized in that, The equipment includes several reinforcing bars and an integral three-unit box girder positioning mesh welding processing device as described in any one of claims 1-9. At least some of the reinforcing bars are arranged to cross and overlap each other on the processing table (1). The box girder positioning mesh welding device is used to weld at least some of the intersections.

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