A high-precision assembly and welding method for T-shaped ribs of a steel box truss composite beam plate unit

Abstract

The present application relates to a kind of high-precision assembly welding methods of steel box truss combination beam plate unit T-shaped rib, is completed by assembly welding platform and submerged-arc welding machine cooperation, two welding stations are provided on the platform surface of assembly welding platform, respectively first welding station and second welding station, bottom support table and back mountain are provided at each welding station, and rib plate jacking mechanism is set at first welding station;High-precision assembly welding method includes the following steps: S1, system establishment and preparation;S2, bottom plate platform positioning;S3, rib plate platform positioning;S4, first welding;S5, assembly turning positioning;S6, second welding;The high-precision assembly welding method of the present application is coordinated controlled according to the positioning parameters calculated by control system according to model, realizes the dynamic adjustment and automatic positioning of bottom plate and rib plate, ensures the position accuracy of bottom plate and the perpendicularity between bottom plate and rib plate, provides good condition for submerged-arc welding, realizes the high-precision, high-precision, high consistency production of T-shaped rib.

Description

Technical Field

[0001] This invention relates to the field of bridge construction technology, and in particular to a high-precision welding method for T-ribs of steel box girder composite beam units. Background Technology

[0002] As bridge spans continue to increase, traditional steel truss girders and steel box girders can no longer meet the load-bearing requirements of ultra-long span road-rail dual-purpose bridges. Therefore, steel box truss composite girders have emerged, which perfectly combine the bending and torsional resistance of steel box girders with the lightweight advantages of steel truss girders, and have great potential application value in ultra-long span road-rail dual-purpose cable-stayed bridges.

[0003] The fabrication of plate units in steel box girder composite beams involves the production of numerous T-ribs. To improve the welding efficiency and quality of these T-ribs, submerged arc welding (SAW) is used instead of manual welding. However, SAW has very strict requirements regarding the welding position, especially for fillet welds. During SAW, granular flux covers the arc and molten pool, requiring the welding position to be basically horizontal or slightly inclined. Otherwise, the flux will leak out, failing to form a protective layer, leading to weld failure and defects such as porosity. If the T-ribs are placed flat on the bottom surface, the fillet welds on both sides are in a horizontal welding position, preventing flux from accumulating in the weld area, exposing the arc, and affecting weld quality.

[0004] Therefore, this invention proposes a high-precision welding method for T-ribs of steel box girder composite beam plate units to solve the above problems. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a high-precision assembly welding method for T-ribs of steel box girder composite beam plate units, so as to realize efficient submerged arc automatic welding of T-ribs and improve the welding quality and welding efficiency of T-ribs.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: a high-precision assembly welding method for T-ribs of steel box girder composite beam plate units, the innovation of which lies in: the assembly welding is completed by the cooperation of a welding platform and a submerged arc welding machine. The welding platform has two welding stations on its surface, namely a first welding station and a second welding station. Each welding station is provided with a base plate support and a backing, and a rib plate pushing mechanism is set at the first welding station; the high-precision assembly welding method includes the following steps: S1. System establishment and preparation: The welding platform and submerged arc welding machine are all controlled by the control system. Based on the structural characteristics of the welding platform, the attitude evaluation model of the T-rib is established. The process parameters of the T-rib to be welded are input into the control system, and the attitude evaluation model calculates the bottom plate positioning parameters and rib plate positioning parameters of the T-rib. S2. Base plate platform positioning: The support of the first welding station is moved to the initial position in advance, and the base plate is hoisted and placed at the first welding station of the assembly welding platform. The support moves and pushes the base plate to move. The tilt angle of the base plate is detected in real time using a distance sensor, a first tactile sensor and a second tactile sensor. When the tilt angle of the base plate reaches the required tilt angle, the support stops moving and the base plate is fixed. S3. Rib plate platform positioning: The rib plate is suspended on the base plate and tilted against the side wall of the mountain. The rib plate pushing mechanism is activated and pushes the rib plate along the side wall of the mountain. The position of the rib plate is detected in real time using the third tactile sensor. When the rib plate is perpendicular to the base plate, the rib plate pushing mechanism stops and the rib plate is fixed. S4. First welding: The upper fillet weld between the rib plate and the base plate is welded by a submerged arc welding machine to form the component; S5, Component Turning and Positioning: The support of the second welding station is moved to the initial position in advance, and the component is hoisted to the second welding station of the assembly welding platform so that the lower corner weld formed between the rib and the base plate faces upward. The support moves and pushes the component to move. The first tactile sensor and the third tactile sensor work together to detect the posture of the component in real time. When the posture is adjusted to the right position, the support stops moving and the component is fixed. S6. Second welding: The lower corner weld of the component facing upward is welded by a submerged arc welding machine to obtain the finished T-rib.

[0007] Furthermore, the platform surface of the welding platform is set horizontally, the base plate support and the backrest are respectively set on both sides of the platform surface in the width direction, and a reference plate is vertically set at one end of the platform surface in the length direction. The base plate support platform includes a support platform body and an electromagnet support plate. The support platform body is fixedly installed on the platform surface of the welding platform. The electromagnet support plate is set on the top surface of the support platform body near the edge of the mountain side and is hinged to the support platform body through a first hinge seat. The support is movably mounted on the platform surface of the welding platform via a guide drive mechanism. The guide drive mechanism includes a guide rail, a slider, a screw, and a nut. The guide rail is fixedly mounted on the platform surface of the welding platform. The slider is fixedly mounted on the bottom of the support and slidably connected to the guide rail. The nut is fixedly mounted on the bottom of the support. The screw is rotatably mounted on the platform surface of the welding platform via a bearing seat. The nut is fitted on the outside of the screw and threadedly connected to the screw. The screw is driven to rotate by a motor and, through the nut, drives the support to move horizontally along the guide rail toward or away from the support platform body. The side wall of the mountain near the base support platform includes an inclined side wall and a vertical side wall arranged sequentially from top to bottom. The inclined side wall is inclined from top to bottom towards the base support platform, and the bottom of the inclined side wall and the top of the vertical side wall are connected to each other to form a horizontal standard line. The rib plate pushing mechanism includes an electromagnet pushing plate and an electric push rod. The electric push rod is installed above the platform surface of the welding platform through a mounting plate. The electromagnet pushing plate is hinged to the telescopic end of the electric push rod through a second hinge seat. The electromagnet pushing plate is driven by the electric push rod to move horizontally closer to or away from the bottom plate support platform. The distance sensor is installed on the support platform body to detect the distance between the backrest and the support platform body; the first tactile sensor is installed on the platform surface of the welding platform between the support platform body and the backrest to detect the position of the base plate on the platform surface of the welding platform; the second tactile sensor is installed at the bottom of the vertical side wall of the backrest to detect the position of the base plate on the backrest; and the third tactile sensor is installed on the inclined side wall of the backrest to detect the position of the rib plate on the backrest.

[0008] Furthermore, in step S1, the process parameters for the T-rib to be welded, including the base plate length, are input into the control system. Base plate width Base plate thickness Rib length Rib width Rib thickness The base plate requires an angle of inclination. The rib angle error range, the base plate positioning error range, and the rib positioning error range.

[0009] Furthermore, in step S1, the positioning parameters of the T-rib's base plate are as follows: when the base plate is at an inclined angle... When the position is positioned on the assembly welding platform, the theoretical horizontal distance between the bottom edge of the base plate and the support platform body is... ; Attitude evaluation model calculates base plate positioning parameters The formula is: in, The angle of inclination of the base plate The vertical distance from the support point of the electromagnet support plate to the base plate to the surface of the welding platform; The rib positioning parameters of the T-rib are as follows: at an inclination angle on the base plate. When the rib is positioned perpendicularly to the base plate on the welding platform, the theoretical vertical distance from the top edge of the rib's bottom surface to the standard line is... ; Attitude evaluation model calculates rib positioning parameters The formula is: in, This is the vertical distance from the standard line to the platform surface of the welding platform.

[0010] Furthermore, the detailed process of positioning the base plate platform in step S2 is as follows: S2-1. After hoisting the base plate horizontally in the length direction and vertically in the width direction to the first welding station of the assembly welding platform, lower the base plate. The base plate is lowered vertically along the vertical side wall of the support platform between the support platform body and the support platform. When the bottom of the base plate reaches the platform surface of the assembly welding platform, the base plate is tilted and abutted against the base plate support platform. At this time, the end of the base plate abuts against the reference plate. The bottom surface of the base plate is supported by the electromagnet support plate. The bottom edge of the bottom surface of the base plate is supported by the platform surface of the assembly welding platform and contacts the first tactile sensor. The first tactile sensor detects the position of the bottom edge of the bottom surface of the base plate. The bottom edge of the top surface of the base plate abuts against the vertical side wall of the support platform and contacts the second tactile sensor. The second tactile sensor detects the position of the bottom edge of the top surface of the base plate. S2-2. Start the motor, move the base plate closer to the support platform body, and push the base plate to move. During the movement of the base plate, the bottom edge of the bottom surface of the base plate moves along the platform surface of the welding platform closer to the support platform body, and the top edge of the top surface of the base plate moves downward along the vertical side wall of the base plate. The first tactile sensor and the second tactile sensor detect the position of the bottom edge of the bottom surface of the base plate and the bottom edge of the top surface of the base plate, respectively. The distance sensor detects the distance between the base plate and the support platform body. The control system calculates the tilt angle of the base plate through the attitude evaluation model. When the tilt angle of the base plate is equal to... When the mountain stops moving, the electromagnet support plate is energized and adsorbs and fixes the base plate.

[0011] Furthermore, the method for calculating the tilt angle of the base plate using the attitude evaluation model is as follows: in, For a moment The tilt angle of the base plate is the angle between the bottom surface of the base plate and the platform surface of the welding platform. For a moment The horizontal distance from the mountain to the support platform body; For a moment The horizontal distance from the bottom edge of the base plate to the support platform body; For a moment The vertical distance from the bottom edge of the top surface of the base plate to the platform surface of the welding platform.

[0012] Furthermore, in step S2-2, when the base plate tilts at an angle... equal At that time, the mountain stopped moving and... and To make a comparison, if If the value is within the positioning error range of the base plate, the electromagnet support plate is energized to attract and fix the base plate. If it exceeds the positioning error range of the base plate, it is determined that the base plate is excessively deformed, and the base plate is lifted off the welding platform for correction.

[0013] Furthermore, the detailed process of positioning the rib plate platform in step S3 is as follows: S3-1. After hoisting the rib plate horizontally in the length direction and vertically in the width direction to the back of the first welding station of the assembly welding platform, lower the rib plate to the inclined side wall of the back of the mountain, then tilt the rib plate so that the bottom surface of the rib plate is in contact with the inclined side wall of the back of the mountain, and then lower the rib plate so that the rib plate slides down the inclined side wall of the back of the mountain to the bottom plate. S3-2. Activate the electric push rod, which pushes the rib plate with an electromagnet. During the movement, the bottom edge of the rib's top surface moves upward along the top surface of the base plate, while the top edge of the rib's bottom surface moves along the inclined side wall against the mountain. The position of the top edge of the rib's bottom surface is detected in real time by a third tactile sensor, and the position signal is transmitted to the control system. When the vertical distance between the position of the top edge of the rib's bottom surface and the standard line equals the rib positioning parameter... When the electromagnet push plate stops moving, the electromagnet push plate is energized and attracts the fixed rib plate.

[0014] Furthermore, in step S3-2, when the vertical distance between the position of the top edge of the bottom surface of the rib and the standard line is equal to the rib positioning parameter... At that time, the electromagnet pusher plate stops moving, and the angle sensor detects the acute angle between the bottom surface of the rib plate and the horizontal plane. ,Will The value and To make a comparison, if If the value is within the rib angle error range, the electromagnet push plate is energized to attract and fix the base plate. If it exceeds the rib angle error range, it is determined that the rib is excessively deformed, and the rib is lifted off the welding platform for correction.

[0015] Furthermore, the detailed process of component flipping and positioning in step S5 is as follows: S5-1. Lift and move the component with the base plate horizontal to the second welding station of the assembly welding platform. Lower the component so that the base plate rests on the electromagnet support plate and the end of the component touches the reference plate. Continue to lower the component so that the base plate slides down along the electromagnet support plate until the bottom edge of the top surface of the base plate touches the vertical side wall of the backing. The bottom edge of the bottom surface of the base plate is supported by the platform surface of the assembly welding platform. S5-2. Start the motor, move it closer to the support platform body, and push the component to move so that the bottom edge of the base plate moves along the platform surface of the welding platform closer to the support platform body. When the horizontal distance between the bottom edge of the base plate detected by the first tactile sensor and the support platform body is... When they are equal, if the third tactile sensor has detected the position signal of the top edge of the bottom surface of the rib, then the vertical distance from the position of the top edge of the bottom surface of the rib detected by the third tactile sensor to the standard line is calculated. and To make a comparison, if If the value is within the rib positioning error range, the posture is adjusted to the correct position, the support stops moving, and the electromagnet support plate is energized to attract and fix the components. If the third tactile sensor does not detect the position signal of the top edge of the rib bottom surface, the support continues to move. When the third tactile sensor detects the position signal of the top edge of the rib bottom surface, and the vertical distance from the position of the top edge of the rib bottom surface detected by the third tactile sensor to the standard line is within the range of the rib positioning error, the support continues to move. When the distances are equal, the support plate stops moving. The horizontal distance between the bottom edge of the base plate, detected by the first tactile sensor, and the support platform body is then measured. and To make a comparison, if If the value is within the positioning error range of the base plate, the posture state is adjusted to the correct position, the support plate stops moving, and the electromagnet support plate is energized to attract and fix the components.

[0016] The advantages of this invention are: (1) Before welding, the assembly welding method of the present invention establishes a posture evaluation model of the T-rib according to the structural characteristics of the assembly welding platform. Based on the input T-rib process parameters, the model calculates the positioning parameters of the T-rib base plate and rib plate, and uses this as the positioning basis of the T-rib base plate and rib plate. During the positioning process of the T-rib base plate and rib plate onto the platform, the distance sensor and multiple tactile sensors are used to detect the position changes of the base plate and rib plate in real time, and the position data signal is fed back to the control system. The control system coordinates the backing and rib plate pushing mechanism according to the positioning parameters calculated by the model, realizes the dynamic adjustment and automatic positioning of the base plate and rib plate, ensures the position accuracy of the base plate and the perpendicularity between the base plate and the rib plate, ensures the accuracy of the fillet weld position, provides good conditions for subsequent submerged arc welding, and realizes high-precision, high-consistency production of T-ribs.

[0017] (2) When positioning the base plate, the welding platform used in the welding method of the present invention utilizes the vertical side wall of the mountain, the platform surface of the welding platform and the base plate support table to achieve three-point positioning of the base plate. The electromagnet support plate on the base plate support table generates magnetic attraction and fixation after being energized, thus preventing the base plate from moving. When positioning the rib plate, the electromagnet push plate pushes the rib plate into place. The base plate and the inclined side wall of the mountain, which have been positioned and fixed, achieve one-sided and one-point bidirectional positioning constraint of the rib plate. The electromagnet push plate generates magnetic attraction and fixation of the rib plate after being energized, thus preventing the rib plate from moving. The operation is simple and the positioning accuracy is high.

[0018] (3) When positioning the platform on the base plate in the assembly welding method of the present invention, the tilt angle of the base plate is evaluated with the bottom sidewall of the base plate, which is not easily deformed, as the object. When the tilt angle meets the tilt angle requirements of the base plate, At this time, the position of the bottom edge of the base plate is compared with the base plate positioning parameters calculated using the base plate as the object, so as to accurately identify whether the base plate has initial deformation before welding, thereby effectively reducing the occurrence of misalignment and forced assembly caused by cumulative errors in the future, and ensuring welding quality.

[0019] (4) When positioning the rib plate on the platform in the assembly welding method of the present invention, the rib plate is first moved to the position based on the pre-calculated rib plate positioning parameters. Then, the tilt state at this time is evaluated by using an angle sensor to identify whether the rib plate has initial deformation, so as to accurately determine whether the perpendicularity between the rib plate and the base plate at this time meets the requirements, and ensure the final welding accuracy and quality. Attached Figure Description

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0021] Figure 1 This is a top view of the welding platform of the present invention.

[0022] Figure 2 This is a cross-sectional view of the welding platform AA of the present invention.

[0023] Figure 3 This is a cross-sectional view of the welding platform BB of the present invention.

[0024] Figure 4 This is a schematic flowchart of the high-precision assembly welding method of the present invention. Detailed Implementation

[0025] 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.

[0026] Example This embodiment provides a high-precision assembly welding method for T-ribs of steel box girder composite beam plate units, which is completed by the assembly welding platform 1 and submerged arc welding machine.

[0027] like Figure 1-3 As shown, the welding platform 1 has two welding stations on both sides of its width direction, namely the first welding station and the second welding station. Each welding station is equipped with a base plate support 2 and a backrest 3, and a rib plate pushing mechanism 4 is set at the first welding station. The platform surface of the welding platform 1 is horizontally set, and the base plate support 2 and the backrest 3 are respectively set on both sides of the platform surface of the welding platform at the corresponding welding station in the width direction. A reference plate 5 is vertically set at one end of the length direction of each welding station on the platform surface of the welding platform 1.

[0028] The base plate support platform 2 includes a support platform body 201 and an electromagnet support plate 202. The support platform body 201 is fixedly installed on the platform surface of the welding platform 1. The electromagnet support plate 202 is located on the top surface of the support platform body 201 near the edge of the support 3, and is hinged to the support platform body 201 through a first hinge seat. A first torsion spring is installed between the electromagnet support plate 202 and the support platform body 201. The two ends of the first torsion spring are respectively connected to the electromagnet support plate 202 and the support platform body 201. The first torsion spring is used to apply elastic force to the electromagnet support plate 202. When the electromagnet support plate 202 does not receive other external forces, the first torsion spring pushes the electromagnet support plate 202 to rotate and return to a horizontal state.

[0029] The support 3 is movably mounted on the platform surface of the welding platform 1 via a guide drive mechanism. The guide drive mechanism includes a guide rail 301, a slider 302, a screw 303, and a nut. The guide rail 301 is fixedly mounted on the platform surface of the welding platform 1. The slider 302 is fixedly mounted on the bottom of the support 3 and is slidably connected to the guide rail 301. The nut is fixedly mounted on the bottom of the support 3. The screw 303 is rotatably mounted on the platform surface of the welding platform 1 via a bearing seat. The nut is fitted on the outside of the screw and threadedly connected to the screw 303. The screw is driven to rotate by a motor 304 and, through the nut, drives the support 3 to move horizontally along the guide rail 301 toward or away from the support platform body 201.

[0030] The side wall of the mountain 3 near the base plate support platform 2 includes an inclined side wall 3a and a vertical side wall 3b arranged sequentially from top to bottom. The inclined side wall 3a is inclined from top to bottom towards the base plate support platform 2. The bottom of the inclined side wall 3a and the top of the vertical side wall 3b are connected to each other to form a horizontal standard line.

[0031] The rib-pushing mechanism 4 includes an electromagnet-pushing plate 401 and an electric push rod 402. The electric push rod 402 is mounted above the platform surface of the welding platform 1 via a mounting plate 403. The electromagnet-pushing plate 401 is hinged to the telescopic end of the electric push rod 402 via a second hinge seat. The electromagnet-pushing plate 401 is driven by the electric push rod 402 to move horizontally closer to or away from the base plate support platform 2. A second torsion spring is installed between the electromagnet-pushing plate 401 and the telescopic end of the electric push rod 402. The two ends of the second torsion spring are respectively connected to the electromagnet-pushing plate 401 and the electric push rod 402. The second torsion spring is used to apply elastic force to the electromagnet-pushing plate 401. When the electromagnet-pushing plate 401 does not receive any other external force, the second torsion spring pushes the electromagnet-pushing plate 401 to rotate and return to the vertical state.

[0032] The welding platform also includes a distance sensor 6, a first tactile sensor 7, a second tactile sensor 8, a third tactile sensor 9, and an angle sensor.

[0033] A distance sensor 6 is installed on the support platform body 201 to detect the distance between the support base 3 and the support platform body 201; a first tactile sensor 7 is installed on the platform surface of the welding platform 1 between the support platform body 201 and the support base 3 to detect the position of the base plate on the platform surface of the welding platform 1; a second tactile sensor 8 is installed at the bottom of the vertical side wall 3b of the support base 3 to detect the position of the base plate on the support base 3; a third tactile sensor 9 is installed on the inclined side wall 3a of the support base 3 to detect the position of the rib plate on the support base 3. An angle sensor is installed on the electromagnet push plate 401, and the angle sensor indirectly detects the angle between the rib plate and the horizontal plane by detecting the angle between the electromagnet push plate 401 and the horizontal plane.

[0034] like Figure 4 As shown, the high-precision assembly welding method includes the following steps: S1. System Establishment and Preparation: The welding platform and submerged arc welding machine are all controlled by the control system. Based on the structural characteristics of the welding platform, the attitude evaluation model of the T-rib is established. The process parameters of the T-rib to be welded are input into the control system, and the attitude evaluation model calculates the base plate positioning parameters and rib plate positioning parameters of the T-rib.

[0035] The process parameters for the T-ribs to be welded include the base plate length. Base plate width Base plate thickness Rib length Rib width Rib thickness The base plate requires an angle of inclination. The rib angle error range, the base plate positioning error range, and the rib positioning error range.

[0036] The positioning parameters for the T-rib base plate are as follows: when the base plate is at an inclination angle... When the position is positioned on the assembly welding platform, the theoretical horizontal distance between the bottom edge of the base plate and the support platform body is... .

[0037] Attitude evaluation model calculates base plate positioning parameters The formula is: in, The angle of inclination of the base plate The vertical distance from the support point of the electromagnet support plate to the base plate to the surface of the welding platform is defined in this embodiment, where the center point of the top surface of the electromagnet support plate is used as the support point of the electromagnet support plate to the base plate.

[0038] The positioning parameters for the T-rib are as follows: on the base plate at an inclined angle... When the rib is positioned perpendicularly to the base plate on the welding platform, the theoretical vertical distance from the top edge of the rib's bottom surface to the standard line is... ; Attitude evaluation model calculates rib positioning parameters The formula is: in, This is the vertical distance from the standard line to the platform surface of the welding platform; The base plate is tilted at an angle When the rib plate is positioned perpendicularly to the base plate on the assembly welding platform, the vertical distance between the top edge of the bottom surface of the rib plate and the bottom edge of the top surface of the base plate is as follows: When the base plate is tilted at an angle When the rib plate is positioned perpendicular to the base plate on the assembly welding platform, the acute angle between the plane passing through the top edge of the bottom surface of the rib plate and the bottom edge of the top surface of the base plate and the vertical side wall of the mountain is considered.

[0039] S2. Base plate platform positioning: The support of the first welding station is moved to the initial position in advance, and the base plate is hoisted and placed at the first welding station of the assembly welding platform. The support moves and pushes the base plate to move. The tilt angle of the base plate is detected in real time using a distance sensor, a first tactile sensor and a second tactile sensor. When the tilt angle of the base plate reaches the required tilt angle, the support stops moving and the base plate is fixed.

[0040] The detailed process of positioning the base platform is as follows: S2-1. After hoisting the base plate horizontally in the length direction and vertically in the width direction above the first welding station of the welding platform, lower the base plate. The base plate is lowered vertically along the vertical side wall of the support platform between the support platform body and the support platform. When the bottom of the base plate reaches the platform surface of the welding platform, the base plate is tilted and pressed against the base plate support platform. During this process, the base plate presses the electromagnet support plate to overcome the elastic force of the first torsion spring and rotate downward until the top surface of the electromagnet support plate is completely in contact with the bottom surface of the base plate. The bottom surface of the base plate is supported by the electromagnet support plate. At this time, one end of the base plate in the length direction abuts against the reference plate. The bottom edge of the bottom surface of the base plate is supported by the platform surface of the welding platform and contacts the first tactile sensor. The first tactile sensor detects the position of the bottom edge of the bottom surface of the base plate. The bottom edge of the top surface of the base plate abuts against the vertical side wall of the support platform and contacts the second tactile sensor. The second tactile sensor detects the position of the bottom edge of the top surface of the base plate.

[0041] S2-2. Start the motor, move the base plate closer to the support platform body, and push the base plate to move. During the movement of the base plate, the bottom surface of the base plate presses down on the electromagnet support plate and rotates downward, causing relative displacement between them. The bottom edge of the bottom surface of the base plate moves along the platform surface of the welding platform closer to the support platform body, and the top edge of the top surface of the base plate moves downward along the vertical side wall of the base plate. The positions of the bottom edge of the bottom surface and the bottom edge of the top surface of the base plate are detected by the first tactile sensor and the second tactile sensor, respectively. The distance sensor detects the distance between the base plate and the support platform body. The control system calculates the tilt angle of the base plate through the attitude evaluation model. The method for calculating the tilt angle of the base plate by the attitude evaluation model is as follows: in, For a moment The tilt angle of the base plate is the angle between the bottom surface of the base plate and the platform surface of the welding platform. For a moment The horizontal distance from the mountain to the support platform body; For a moment The horizontal distance from the bottom edge of the base plate to the support platform body; For a moment The vertical distance from the bottom edge of the top surface of the base plate to the platform surface of the welding platform.

[0042] When the tilt angle of the base plate is equal to At that time, the mountain stopped moving and... and To make a comparison, if If the value is within the positioning error range of the base plate, the electromagnet support plate is energized to attract and fix the base plate. If it exceeds the positioning error range of the base plate, it is determined that the base plate is excessively deformed, and the base plate is lifted off the welding platform for correction.

[0043] S3. Rib Platform Positioning: The rib is suspended on the base plate and tilted against the side wall of the mountain. The rib pushing mechanism is activated and pushes the rib along the side wall of the mountain. The position of the rib is detected in real time using a third tactile sensor. When the rib is perpendicular to the base plate, the rib pushing mechanism stops and the rib is fixed.

[0044] The detailed process of rib plate platform positioning is as follows: S3-1. After hoisting the rib plate horizontally in the length direction and vertically in the width direction to the back of the first welding station of the assembly welding platform, lower the rib plate to the inclined side wall of the back of the mountain, then tilt the rib plate so that the bottom surface of the rib plate is in contact with the inclined side wall of the back of the mountain, and then lower the rib plate so that the rib plate slides down the inclined side wall of the back of the mountain to the bottom plate. S3-2. Start the electric push rod. The electromagnet push plate moves horizontally closer to the rib plate. The rib plate uses its own weight to press the electromagnet push plate to rotate until the electromagnet push plate is completely in contact with the bottom surface of the rib plate. Then the electromagnet push plate continues to move horizontally, pushing the rib plate to move. During the movement of the rib plate, the bottom edge of the top surface of the rib plate moves upward along the top surface of the base plate. At the same time, the top edge of the bottom surface of the rib plate moves along the inclined side wall of the mountain. The position of the top edge of the bottom surface of the rib plate is detected in real time by the third tactile sensor and the position signal is transmitted to the control system.

[0045] When the vertical distance between the top edge of the bottom surface of the rib and the standard line is equal to the rib positioning parameter At that time, the electromagnet pusher plate stops moving, and the angle sensor detects the acute angle between the bottom surface of the rib plate and the horizontal plane. ,Will The value and To make a comparison, if If the value is within the rib angle error range, the electromagnet push plate is energized to attract and fix the base plate. If it exceeds the rib angle error range, it is determined that the rib is excessively deformed, and the rib is lifted off the welding platform for correction.

[0046] S4. First Welding: The upper fillet weld between the rib and the base plate is welded using a submerged arc welding machine to form the assembly. During submerged arc welding, welding begins from the end of the upper fillet weld closest to the reference plate. and The smaller value in the range is used as the welding length.

[0047] S5. Component Turnover Positioning: The support of the second welding station is moved to the initial position in advance, and the component is hoisted to the second welding station of the assembly welding platform so that the lower corner weld formed between the rib and the base plate faces upward. The support moves and pushes the component to move. The first tactile sensor and the third tactile sensor work together to detect the posture status of the component in real time. When the posture status is adjusted to the right position, the support stops moving and the component is fixed.

[0048] The detailed process of component repositioning is as follows: S5-1. Lift and move the component with the base plate horizontal to the second welding station of the assembly welding platform. Lower the component so that the base plate rests on the electromagnet support plate, with one end of the component along its length abutting against the reference plate. Continue to lower the component and adjust its angle. Under the action of gravity, the base plate pushes the electromagnet support plate to rotate downwards, so that the bottom of the base plate aligns with the bottom of the vertical side wall of the mountain. Then, let the base plate slide down along the electromagnet support plate at an angle until the bottom edge of the top surface of the base plate abuts against the vertical side wall of the mountain. The bottom edge of the bottom surface of the base plate is supported by the platform surface of the assembly welding platform.

[0049] S5-2. Start the motor, move it closer to the support platform body, and push the components to move so that the bottom edge of the base plate moves along the platform surface of the welding platform closer to the support platform body.

[0050] When the horizontal distance between the bottom edge of the base plate detected by the first tactile sensor and the support platform body is... If the values ​​are equal, and the third tactile sensor has already detected the position signal of the top edge of the bottom surface of the rib, then the vertical distance from the position of the top edge of the bottom surface of the rib detected by the third tactile sensor to the standard line is calculated. and To make a comparison, if If the value is within the rib positioning error range, the posture is adjusted to the correct position, the support stops moving, and the electromagnet support plate is energized to attract and fix the components. If the third tactile sensor does not detect the position signal of the top edge of the rib bottom surface, the support continues to move. When the third tactile sensor detects the position signal of the top edge of the rib bottom surface, and the vertical distance from the position of the top edge of the rib bottom surface detected by the third tactile sensor to the standard line is within the range of the rib positioning error, the support continues to move. When the distances are equal, the support plate stops moving. The horizontal distance between the bottom edge of the base plate, detected by the first tactile sensor, and the support platform body is then measured. and To make a comparison, if If the value is within the positioning error range of the base plate, the posture state is adjusted to the correct position, the support plate stops moving, and the electromagnet support plate is energized to attract and fix the components.

[0051] S6. Second Welding: The submerged arc welding machine is used to weld the upper-facing lower corner weld of the component. When welding with the submerged arc welding machine, welding begins from the end of the upper-facing lower corner weld closest to the reference plate. and The smaller value in the range is used as the welding length, and the T-rib finished product is obtained after welding.

[0052] The high-precision assembly welding method for the T-ribs of the steel box girder composite beam unit realizes efficient submerged arc welding of the T-ribs, improving the welding quality and efficiency of the T-ribs.

[0053] 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 high-precision welding method for T-ribs of steel box girder composite beam plate units, characterized in that: The high-precision assembly welding method is completed by the cooperation of an assembly welding platform and a submerged arc welding machine. The assembly welding platform has two welding stations on its surface, namely the first welding station and the second welding station. Each welding station is equipped with a base plate support and a backing, and a rib plate pushing mechanism is set at the first welding station. The high-precision assembly welding method includes the following steps: S1. System establishment and preparation: The assembly welding platform and submerged arc welding machine are controlled by the same control system. Based on the structural characteristics of the assembly welding platform, the attitude evaluation model of the T-rib is established. The process parameters of the T-rib to be welded are input into the control system, and the attitude evaluation model calculates the bottom plate positioning parameters and rib plate positioning parameters of the T-rib. S2. Base plate platform positioning: The support of the first welding station is moved to the initial position in advance, and the base plate is hoisted and placed at the first welding station of the assembly welding platform. The support moves and pushes the base plate to move. The tilt angle of the base plate is detected in real time using a distance sensor, a first tactile sensor and a second tactile sensor. When the tilt angle of the base plate reaches the required tilt angle, the support stops moving and the base plate is fixed. S3. Rib plate platform positioning: The rib plate is suspended on the base plate and tilted against the side wall of the mountain. The rib plate pushing mechanism is activated and pushes the rib plate along the side wall of the mountain. The position of the rib plate is detected in real time using the third tactile sensor. When the rib plate is perpendicular to the base plate, the rib plate pushing mechanism stops and the rib plate is fixed. S4. First welding: The upper fillet weld between the rib plate and the base plate is welded by a submerged arc welding machine to form the component; S5, Component Turning and Positioning: The support of the second welding station is moved to the initial position in advance, and the component is hoisted to the second welding station of the assembly welding platform so that the lower corner weld formed between the rib and the base plate faces upward. The support moves and pushes the component to move. The first tactile sensor and the third tactile sensor work together to detect the posture of the component in real time. When the posture is adjusted to the right position, the support stops moving and the component is fixed. S6. Second welding: The lower corner weld of the component facing upward is welded by a submerged arc welding machine to obtain the finished T-rib.

2. The high-precision assembly welding method for T-ribs of steel box girder composite beam plate units according to claim 1, characterized in that: The platform surface of the welding platform is set horizontally, and the base plate support and the backrest are respectively set on both sides of the platform surface in the width direction. A reference plate is set vertically at one end of the platform surface in the length direction. The base plate support platform includes a support platform body and an electromagnet support plate. The support platform body is fixedly installed on the platform surface of the welding platform. The electromagnet support plate is set on the top surface of the support platform body near the edge of the mountain side and is hinged to the support platform body through a first hinge seat. The support is movably mounted on the platform surface of the welding platform via a guide drive mechanism. The guide drive mechanism includes a guide rail, a slider, a screw, and a nut. The guide rail is fixedly mounted on the platform surface of the welding platform. The slider is fixedly mounted on the bottom of the support and slidably connected to the guide rail. The nut is fixedly mounted on the bottom of the support. The screw is rotatably mounted on the platform surface of the welding platform via a bearing seat. The nut is fitted on the outside of the screw and threadedly connected to the screw. The screw is driven to rotate by a motor and, through the nut, drives the support to move horizontally along the guide rail toward or away from the support platform body. The side wall of the mountain near the base support platform includes an inclined side wall and a vertical side wall arranged sequentially from top to bottom. The inclined side wall is inclined from top to bottom towards the base support platform, and the bottom of the inclined side wall and the top of the vertical side wall are connected to each other to form a horizontal standard line. The rib plate pushing mechanism includes an electromagnet pushing plate and an electric push rod. The electric push rod is installed above the platform surface of the welding platform through a mounting plate. The electromagnet pushing plate is hinged to the telescopic end of the electric push rod through a second hinge seat. The electromagnet pushing plate is driven by the electric push rod to move horizontally closer to or away from the bottom plate support platform. The distance sensor is installed on the support platform body to detect the distance between the backrest and the support platform body; the first tactile sensor is installed on the platform surface of the welding platform between the support platform body and the backrest to detect the position of the base plate on the platform surface of the welding platform; the second tactile sensor is installed at the bottom of the vertical side wall of the backrest to detect the position of the base plate on the backrest; and the third tactile sensor is installed on the inclined side wall of the backrest to detect the position of the rib plate on the backrest.

3. The high-precision assembly welding method for T-ribs of steel box girder composite beam plate units according to claim 2, characterized in that: In step S1, the process parameters for the T-rib to be welded, including the base plate length, are input into the control system. Base plate width Base plate thickness Rib length Rib width Rib thickness The base plate requires an angle of inclination. The rib angle error range, the base plate positioning error range, and the rib positioning error range.

4. The high-precision assembly welding method for the T-ribs of the steel box girder composite beam plate unit according to claim 3, characterized in that: In step S1, the base plate positioning parameters of the T-rib are as follows: when the base plate is at an inclined angle... When the position is positioned on the assembly welding platform, the theoretical horizontal distance between the bottom edge of the base plate and the support platform body is... ; Attitude evaluation model calculates base plate positioning parameters The formula is: in, The angle of inclination of the base plate The vertical distance from the support point of the electromagnet support plate to the base plate to the surface of the welding platform; The rib positioning parameters of the T-rib are as follows: at an inclination angle on the base plate. When the rib is positioned perpendicularly to the base plate on the welding platform, the theoretical vertical distance from the top edge of the rib's bottom surface to the standard line is... ; Attitude evaluation model calculates rib positioning parameters The formula is: in, This is the vertical distance from the standard line to the platform surface of the welding platform.

5. The high-precision assembly welding method for the T-ribs of the steel box girder composite beam plate unit according to claim 4, characterized in that: The detailed process of positioning the base plate platform in step S2 is as follows: S2-1. After hoisting the base plate horizontally in the length direction and vertically in the width direction to the first welding station of the assembly welding platform, lower the base plate. The base plate is lowered vertically along the vertical side wall of the support platform between the support platform body and the support platform. When the bottom of the base plate reaches the platform surface of the assembly welding platform, the base plate is tilted and abutted against the base plate support platform. At this time, the end of the base plate abuts against the reference plate. The bottom surface of the base plate is supported by the electromagnet support plate. The bottom edge of the bottom surface of the base plate is supported by the platform surface of the assembly welding platform and contacts the first tactile sensor. The first tactile sensor detects the position of the bottom edge of the bottom surface of the base plate. The bottom edge of the top surface of the base plate abuts against the vertical side wall of the support platform and contacts the second tactile sensor. The second tactile sensor detects the position of the bottom edge of the top surface of the base plate. S2-2. Start the motor, move the base plate closer to the support platform body, and push the base plate to move. During the movement of the base plate, the bottom edge of the bottom surface of the base plate moves along the platform surface of the welding platform closer to the support platform body, and the top edge of the top surface of the base plate moves downward along the vertical side wall of the base plate. The first tactile sensor and the second tactile sensor detect the position of the bottom edge of the bottom surface of the base plate and the bottom edge of the top surface of the base plate, respectively. The distance sensor detects the distance between the base plate and the support platform body. The control system calculates the tilt angle of the base plate through the attitude evaluation model. When the tilt angle of the base plate is equal to... When the mountain stops moving, the electromagnet support plate is energized and adsorbs and fixes the base plate.

6. The high-precision assembly welding method for T-ribs of steel box girder composite beam plate units according to claim 5, characterized in that: The method for calculating the tilt angle of the base plate using the attitude evaluation model is as follows: in, For a moment The tilt angle of the base plate is the angle between the bottom surface of the base plate and the platform surface of the welding platform. For a moment The horizontal distance from the mountain to the support platform body; For a moment The horizontal distance from the bottom edge of the base plate to the support platform body; For a moment The vertical distance from the bottom edge of the top surface of the base plate to the platform surface of the welding platform.

7. The high-precision assembly welding method for T-ribs of steel box girder composite beam plate units according to claim 6, characterized in that: In step S2-2, when the base plate tilt angle equal At that time, the mountain stopped moving and... and To make a comparison, if If the value is within the positioning error range of the base plate, the electromagnet support plate is energized to attract and fix the base plate. If it exceeds the positioning error range of the base plate, it is determined that the base plate is excessively deformed, and the base plate is lifted off the welding platform for correction.

8. The high-precision assembly welding method for the T-ribs of the steel box girder composite beam unit according to claim 4, characterized in that: The detailed process of positioning the rib plate platform in step S3 is as follows: S3-1. After hoisting the rib plate horizontally in the length direction and vertically in the width direction to the back of the first welding station of the assembly welding platform, lower the rib plate to the inclined side wall of the back of the mountain, then tilt the rib plate so that the bottom surface of the rib plate is in contact with the inclined side wall of the back of the mountain, and then lower the rib plate so that the rib plate slides down the inclined side wall of the back of the mountain to the bottom plate. S3-2. Activate the electric push rod, which pushes the rib plate with an electromagnet. During the movement, the bottom edge of the rib's top surface moves upward along the top surface of the base plate, while the top edge of the rib's bottom surface moves along the inclined side wall against the mountain. The position of the top edge of the rib's bottom surface is detected in real time by a third tactile sensor, and the position signal is transmitted to the control system. When the vertical distance between the position of the top edge of the rib's bottom surface and the standard line equals the rib positioning parameter... When the electromagnet push plate stops moving, the electromagnet push plate is energized and attracts the fixed rib plate.

9. The high-precision assembly welding method for T-ribs of steel box girder composite beam plate units according to claim 8, characterized in that: In step S3-2, the vertical distance between the top edge of the bottom surface of the rib and the standard line is equal to the rib positioning parameter. At that time, the electromagnet pusher plate stops moving, and the angle sensor detects the acute angle between the bottom surface of the rib plate and the horizontal plane. ,Will The value and To make a comparison, if If the value is within the rib angle error range, the electromagnet push plate is energized to attract and fix the base plate. If it exceeds the rib angle error range, it is determined that the rib is excessively deformed, and the rib is lifted off the welding platform for correction.

10. The high-precision assembly welding method for T-ribs of steel box girder composite beam plate units according to claim 1, characterized in that: The detailed process of component flipping and positioning in step S5 is as follows: S5-1. Lift and move the component with the base plate horizontal to the second welding station of the assembly welding platform. Lower the component so that the base plate rests on the electromagnet support plate and the end of the component touches the reference plate. Continue to lower the component so that the base plate slides down along the electromagnet support plate until the bottom edge of the top surface of the base plate touches the vertical side wall of the backing. The bottom edge of the bottom surface of the base plate is supported by the platform surface of the assembly welding platform. S5-2. Start the motor, move it closer to the support platform body, and push the component to move so that the bottom edge of the base plate moves along the platform surface of the welding platform closer to the support platform body. When the horizontal distance between the bottom edge of the base plate detected by the first tactile sensor and the support platform body is... When they are equal, if the third tactile sensor has detected the position signal of the top edge of the bottom surface of the rib, then the vertical distance from the position of the top edge of the bottom surface of the rib detected by the third tactile sensor to the standard line is calculated. and To make a comparison, if If the value is within the rib positioning error range, the posture is adjusted to the correct position, the support stops moving, and the electromagnet support plate is energized to attract and fix the components. If the third tactile sensor does not detect the position signal of the top edge of the rib bottom surface, the support continues to move. When the third tactile sensor detects the position signal of the top edge of the rib bottom surface, and the vertical distance from the position of the top edge of the rib bottom surface detected by the third tactile sensor to the standard line is within the range of the rib positioning error, the support continues to move. When the distances are equal, the support plate stops moving. The horizontal distance between the bottom edge of the base plate, detected by the first tactile sensor, and the support platform body is then measured. and To make a comparison, if If the value is within the positioning error range of the base plate, the posture state is adjusted to the correct position, the support plate stops moving, and the electromagnet support plate is energized to attract and fix the components.

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