Welding device for reinforcing structures and welding process

Abstract

This application relates to the field of welding equipment technology, and more particularly to a welding device and welding process for reinforced concrete structures. The welding device includes: a welding assembly comprising a mounting frame and a first welding head and a second welding head insulated from each other and disposed on the mounting frame. The first and second welding heads have a height difference in a first direction and form a mounting cavity. The first welding head has a first arcuate surface, and the second welding head has a second arcuate surface. The first arcuate surface contacts one surface of two individual reinforcing bars at a welding point formed by their intersection, and the second arcuate surface contacts the other surface. A power supply assembly includes a power supply component and a first conductive connector and a second conductive connector connected to the power supply component. The power supply component supplies power to the first and second welding heads through the first and second conductive connectors respectively, forming a resistance welding circuit acting on the welding point. The welding device provided by this application simplifies the operation steps of reinforcing bar connection, thereby improving the construction efficiency of reinforcing bar connection.

Description

Technical Field

[0001] This application relates to the field of welding equipment technology, and in particular to a welding device and welding process for reinforced concrete structures. Background Technology

[0002] Steel bars are core components of modern construction projects. They are mostly made of carbon steel or low alloy steel and have ribs on the surface to enhance their bond with concrete. They are widely used in bridges, high-rise buildings, tunnels and other projects. The strength of the horizontal and vertical connections of multiple steel bars and the efficiency of construction are crucial to the quality of the project.

[0003] In related technologies, the intersection points of intersecting horizontal and vertical steel bars are usually fixed by binding with wire. This method requires multiple steps, including pulling, cutting, and binding, during operation.

[0004] However, the wire binding connection method has the problem of complicated operation steps, which greatly reduces the construction efficiency of steel bar connection and is difficult to adapt to the construction rhythm of modern construction projects. Summary of the Invention

[0005] This application provides a welding device and welding process for reinforced steel structures, which can simplify the operation steps of rebar connection and thus improve the construction efficiency of rebar connection.

[0006] To achieve the above objectives, the technical solution of this application is as follows: In a first aspect, this application provides a welding apparatus for a reinforced steel structure, the reinforced steel structure including a plurality of steel reinforcement units, at least two steel reinforcement units being intersected to form a welding point, the welding apparatus including: a welding assembly including a mounting frame and a first welding head and a second welding head insulated from each other and disposed on the mounting frame, the first welding head and the second welding head having a height difference in a first direction and forming a mounting cavity to accommodate the two steel reinforcement units intersecting to form the welding point, the first welding head having a first arcuate surface, the second welding head having a second arcuate surface, the first arcuate surface contacting one surface of the two steel reinforcement units intersecting to form the welding point, and the second arcuate surface contacting the other surface of the two steel reinforcement units intersecting to form the welding point; a power supply assembly including a power supply component and a first conductive connector and a second conductive connector connected to the power supply component, the first conductive connector being connected to the first welding head, and the second conductive connector being connected to the second welding head to form a resistance welding circuit acting on the welding point.

[0007] In one possible implementation, the welding apparatus for reinforced steel structures provided in this application has a first welding head and a second welding head as an integral structure.

[0008] In one possible implementation, the welding apparatus for reinforced steel structures provided in this application has a first welding head and a second welding head that are offset from each other in a first direction.

[0009] In one possible implementation, the welding device for reinforcing steel structures provided in this application has a first welding head arranged in pairs and symmetrically distributed on both sides of a second welding head in a second direction, the second direction intersecting with the first direction.

[0010] In one possible implementation, the welding apparatus for reinforcing steel structures provided in this application includes a mounting frame comprising pairs of insulating connectors, each insulating connector having opposing first and second ends in a first direction, a first welding head connected to the first end, and a second welding head connected to the second end; wherein at least two pairs of insulating connectors have different extension lengths in the first direction, and the first end of the insulating connector is detachably connected to the first welding head, and the second end is detachably connected to the second welding head; and / or, the paired second ends extend in a direction toward each other in the second direction to connect to opposing sides of the second welding head in the second direction, the second ends of at least two pairs of insulating connectors have different extension lengths in the second direction, the first end is detachably connected to the first welding head, and the second end is detachably connected to the second welding head.

[0011] In one possible implementation, the welding device for steel reinforcement structures provided in this application has a first arc-shaped surface recessed in a direction away from the second arc-shaped surface, and a second arc-shaped surface recessed in a direction away from the first arc-shaped surface; the axis of the first arc-shaped surface and the axis of the second arc-shaped surface are spatially intersecting.

[0012] In one possible implementation, the welding apparatus for reinforced steel structures provided in this application further includes a gripper connected to the side of the second welding head away from the second arcuate surface; at least a portion of the power supply assembly is integrally formed with the gripper.

[0013] In one possible implementation, the welding apparatus for steel reinforcement structures provided in this application further includes a power supply component that is communicatively connected to a power supply element. The power supply switch is embedded in the end of the gripping member away from the second welding head, and the power supply element is embedded in the gripping member.

[0014] Secondly, this application provides a welding process for reinforced concrete structures, comprising: The above-mentioned welding device for reinforced steel structures supports one of the steel bars by means of a first welding head and presses a second welding head onto another intersecting steel bar, so that the two steel bars abut against each other at the welding point. The power supply components are turned on, and the welding device forms a resistance welding circuit that acts on the welding point to generate resistance heat, so that the two steel bars melt at the welding point. Maintain the preset time and apply pressure to the preset pressure value through the second welding head to complete the welding.

[0015] In one possible implementation, the welding process for reinforced concrete structures provided in this application further includes, before the steps of maintaining a preset time and applying pressure to a preset pressure value through a second welding head to complete the welding: Determine at least one of the preset duration and preset pressure value based on the target information; The target information includes at least one of the following: the diameter of the individual steel bar, its material, its welding strength, and its welding current.

[0016] This application provides a welding device and welding process for reinforced concrete structures. The welding device includes a welding assembly and a power supply assembly. The welding device includes a mounting frame and a first welding head and a second welding head insulated from each other on the mounting frame. The insulation of the first and second welding heads effectively prevents short-circuit faults. The first and second welding heads have a height difference in a first direction, forming a mounting cavity to accommodate two intersecting steel rebars forming a welding point, thereby achieving rapid positioning of the welding point. The first welding head has a first arc-shaped surface, and the second welding head has a second arc-shaped surface. The first arc-shaped surface contacts one surface of the two intersecting steel rebars forming the welding point, and the second arc-shaped surface contacts the other surface of the two intersecting steel rebars forming the welding point. Combined with the power supply assembly and the first and second conductive connectors to form a stable resistance welding circuit, it can achieve efficient and stable welding of the intersecting points of two steel rebars while stabilizing the individual steel rebars, simplifying the operation steps of steel rebar connection and thus improving the construction efficiency of steel rebar connection. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a structural schematic diagram of a welding device for reinforced concrete structures provided in an embodiment of this application; Figure 2 for Figure 1 Another perspective illustration; Figure 3 This is a schematic diagram showing the arrangement of individual steel bars in an embodiment of this application; Figure 4 A flowchart of a welding process for reinforced concrete structures provided in an embodiment of this application.

[0019] Explanation of reference numerals in the attached figures: 10 - Welding equipment; 110 - Mounting bracket; 111 - Insulating connector; 111a - First end; 111b - Second end; 120 - First welding head; 121 - First arc-shaped surface; 130 - Second welding head; 131 - Second arc-shaped surface; 140 - Holding member; 21 - Individual steel reinforcement; 22 - Welding point; X - First direction; Y - Second direction.

[0020] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the preferred embodiments of this application will be described in more detail below with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0022] It should be noted that in the description of the embodiments of this application, the terms "upper", "lower", "inner", "outer" and other terms indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of description, and do not indicate or imply that the device or component must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the embodiments of this application.

[0023] Furthermore, it should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0024] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "fixation," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0025] In related technologies, the intersection points of intersecting horizontal and vertical reinforcing bars are usually fixed by binding with wire. This method requires multiple steps, including pulling, cutting, and binding the wire. However, the wire binding connection method is cumbersome, significantly reducing the construction efficiency of reinforcing bar connections and making it difficult to adapt to the construction pace of modern building projects.

[0026] In view of this, the welding device and welding process for reinforced concrete structures provided in this application include a welding assembly and a power supply assembly. The welding device includes a mounting frame and a first welding head and a second welding head that are insulated from each other on the mounting frame. The insulated first welding head and the second welding head can effectively avoid short circuit faults. The first welding head and the second welding head have a height difference in a first direction and form a mounting cavity to accommodate two intersecting steel rebars forming a welding point, thereby achieving rapid positioning of the welding point to be welded. The first welding head has a first arc-shaped surface, and the second welding head has a second arc-shaped surface. The first arc-shaped surface contacts one surface of the two intersecting steel rebars forming the welding point, and the second arc-shaped surface contacts the other surface of the two intersecting steel rebars forming the welding point. In conjunction with the power supply assembly and the first and second conductive connectors to form a stable resistance welding circuit, efficient and stable welding of the intersection point of two steel rebars can be achieved while stabilizing the steel rebars. This simplifies the operation steps of steel rebar connection and improves the construction efficiency of steel rebar connection.

[0027] The present application will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0028] See Figures 1 to 3 This application provides a welding device 10 for reinforced steel structures. The reinforced steel structure includes multiple steel reinforcement units 21, with at least two steel reinforcement units 21 intersecting to form welding points 22. It should be noted that in actual construction, the number of steel reinforcement units 21 can be two, three, or more, and the steel reinforcement units 21 can be arranged in a crisscross pattern. For example, in different components such as building floor slabs, beams, and columns, the steel reinforcement units 21 can form various intersecting forms such as a grid or truss. The intersection of the steel reinforcement units 21 can be perpendicular or non-perpendicular and inclined, and the intersection will form welding points 22 that need to be welded and fixed.

[0029] The welding apparatus 10 includes a welding assembly and a power supply assembly (not shown in the figure). The welding assembly includes a mounting frame 110 and a first welding head 120 and a second welding head 130 insulated from each other and disposed on the mounting frame 110. The first welding head 120 and the second welding head 130 have a height difference in a first direction X and form a mounting cavity to accommodate two intersecting steel rebar units 21 that form a welding point 22. The first welding head 120 has a first arc-shaped surface 121, and the second welding head 130 has a second arc-shaped surface 131. The first arc-shaped surface 121 contacts one surface of the two intersecting steel rebar units 21 that form the welding point 22, and the second arc-shaped surface 131 contacts the other surface of the two intersecting steel rebar units 21 that form the welding point 22. The power supply assembly includes a power supply component and a first conductive connector and a second conductive connector connected to the power supply component. The first conductive connector is connected to the first welding head 120, and the second conductive connector is connected to the second welding head 130 to form a resistance welding circuit acting on the welding point 22. Through the coordinated operation of the welding components and the power supply components, resistance welding of welding point 22 is achieved, ensuring that the welding process is efficient and stable.

[0030] The welding assembly, which is a component that contacts the steel bar unit 21 and completes the welding operation, may include a mounting frame 110 and a first welding head 120 and a second welding head 130 set on the mounting frame 110. The mounting frame 110 serves to support and fix the first welding head 120 and the second welding head 130, providing a stable mounting base for both, reducing the probability of positioning deviation caused by welding head shaking during the welding process, and thus avoiding affecting the welding quality and efficiency.

[0031] Optionally, the mounting frame 110 can be a split frame or an integrated frame. When the mounting frame 110 is a split frame, the first welding head 120 and the second welding head 130 can be connected to a portion of the mounting frame 110 respectively. When the mounting frame 110 is an integrated frame, the first welding head 120 and the second welding head 130 can be integrated into the integrated frame.

[0032] In addition, the mounting bracket 110 may have a control part that is easy for the operator to hold, so that the operator can hold it firmly with one or two hands and flexibly adjust the angle and position of the welding device 10.

[0033] To prevent short circuits during welding and ensure the safety and stability of the welding operation, the first welding head 120 and the second welding head 130 are insulated from each other on the mounting frame 110. Specifically, insulation can be achieved by installing insulating components at the connection points between the mounting frame 110 and the first welding head 120 and the second welding head 130, or by applying an insulating coating to the connection points. This ensures that no current path is formed between the first welding head 120 and the second welding head 130, thereby effectively preventing short circuits and avoiding problems such as device damage and welding interruptions caused by short circuits, thus ensuring the continuous operation of the welding operation.

[0034] To achieve rapid positioning of the welding point 22 and reduce the difficulty of manual operation, the first welding head 120 and the second welding head 130 have a height difference in the first direction X, forming an installation cavity between them that is adapted to the intersecting steel bar individual 21. The height of this installation cavity matches the sum of the diameters of the two intersecting steel bar individual 21 that form the welding point 22. Here, "matching" means that the height of the installation cavity is greater than or equal to the sum of the diameters of the two intersecting steel bar individual 21. This allows for a reasonable gap to be reserved for the insertion of the two steel bar individual 21, making it convenient for operators to quickly place the steel bar individual 21 into the installation cavity, while preventing the steel bar individual 21 from shifting or shaking within the installation cavity due to excessive gap. It can just accommodate the two intersecting steel bar individual 21, so that the welding point 22 can be automatically located in the effective area of ​​the welding device 10 without the need for repeated manual adjustment of the position of the steel bar individual 21, greatly shortening the positioning time and significantly improving the efficiency of the welding operation. Here, the first direction X can be understood as the height direction of the steel bar structure, or as the stacking direction of the two steel bar individual 21.

[0035] Optionally, the first welding head 120 may include a plate-like structure, a block-like structure, etc. The second welding head 130 may include a plate-like structure, a block-like structure, etc.

[0036] In specific implementation, to quickly locate the welding point 22, the first welding head 120 can have a first arc-shaped surface 121, and the second welding head 130 can have a second arc-shaped surface 131. The first arc-shaped surface 121 is in surface contact with one of the two steel rebar units 21 that intersect to form the welding point 22, and the second arc-shaped surface 131 is in surface contact with the other of the two steel rebar units 21. Compared with the traditional point contact or line contact welding head design, surface contact can significantly increase the contact area between the welding head and the steel rebar unit 21. On the one hand, it can effectively disperse the welding current and avoid excessive local current that could cause the steel rebar unit 21 to burn out and the welding head to be damaged. On the other hand, it can ensure that the welding heat is evenly transferred to the welding point 22, ensuring that the welding point 22 is heated evenly, effectively reducing the generation of welding defects such as slag inclusions, incomplete penetration, and cracks, and achieving a stable welding effect.

[0037] It should also be noted that by setting the first arc-shaped surface 121 and the second arc-shaped surface 131, in specific operations, the operator can first align the first arc-shaped surface 121 of the first welding head 120 with the lower one of the two intersecting steel bar units 21, and use the arc structure of the first arc-shaped surface 121 to lift the bottom of the lower steel bar unit 21, so that the lower steel bar unit 21 is detached from the construction base and is in a stable supported state; then, rotate the entire welding device 10, and adjust the angle of the welding device 10 during the rotation, so that the second arc-shaped surface 131 of the second welding head 130 gradually comes into contact with the top of the upper one of the two steel bar units 21, until the first arc-shaped surface 121 is in complete surface contact with the bottom of the lower steel bar unit 21 and the second arc-shaped surface 131 is in complete surface contact with the top of the upper steel bar unit 21, so that the two steel bar units 21 can maintain an intersecting posture, thereby forming a welding point 22 and completing the positioning operation. The entire positioning process requires no additional positioning tools. Only the action of the shovel on the first arc-shaped surface 121 and the rotational adjustment of the welding device 10 are needed to achieve rapid and precise positioning of the two intersecting steel reinforcement units 21, simplifying the operation. In other words, by setting the first arc-shaped surface 121 and the second arc-shaped surface 131, operators can quickly complete the support, alignment, and fixation of the two intersecting steel reinforcement units 21, reducing the difficulty of operation and significantly improving positioning efficiency and accuracy.

[0038] Optionally, the orthographic projections of the first welding head 120 and the second welding head 130 in the first direction X can be at least partially staggered. For example, the end of the first welding head 120 away from the mounting frame 110 can be provided with an inclined surface connected to the first arc-shaped surface 121. The inclined surface smoothly transitions with the first arc-shaped surface 121, and the inclined surface is inclined towards the construction base surface. At the same time, the orthographic projection of the end of the first welding head 120 away from the mounting frame 110 in the first direction X can be staggered from the orthographic projection of the second welding head 130 by a preset distance. This facilitates the first welding head 120 to scoop up the bottom of the lower steel bar unit 21. The inclined surface can quickly extend into the gap between the lower steel bar unit 21 and the construction base surface, playing a guiding and leveraging role, reducing the force required for the scooping operation, and avoiding mutual interference between the second welding head 130 and the first welding head 120 during the scooping process. This ensures that when the welding device 10 is rotated, the second welding head 130 can smoothly fit the top of the upper steel bar unit 21 without affecting the smoothness of the positioning operation, further improving the convenience and reliability of the positioning process.

[0039] The power supply component serves as the power source for the welding device 10, providing a stable current for the welding operation. It may include a power supply component and a first conductive connector and a second conductive connector connected to the power supply component. One end of the first conductive connector is connected to the output end of the power supply component, and the other end is connected to the first welding head 120. One end of the second conductive connector is connected to the other output end of the power supply component, and the other end is firmly connected to the second welding head 130. This ensures good contact between the conductive connector and the welding head, reduces contact resistance, and avoids problems such as current loss and insufficient welding heat caused by poor contact.

[0040] Optionally, the power supply component can be integrated with the welding assembly or installed separately. The power supply component may include a rechargeable lithium battery or an AC power module, and it integrates a current adjustment button and a power switch. This allows for flexible adjustment of the output current based on the diameter and material of the individual steel bar 21, adapting to the welding requirements of different steel bar specifications. It also features overload protection and short-circuit protection functions, further enhancing the safety of the welding operation. The first and second conductive connectors may include copper braided wires or copper terminals, with an outer layer of high-temperature resistant insulating tubing to ensure the stability and safety of the power supply circuit.

[0041] Optionally, the first welding head 120 can be used as the positive welding head, and the second welding head 130 can be used as the negative welding head. When the welding device 10 is operating, the power supply unit supplies power to the first welding head 120 through the first conductive connector and simultaneously supplies power to the second welding head 130 through the second conductive connector, so that a stable potential difference is formed between the first welding head 120 and the second welding head 130. Since the first welding head 120 and the second welding head 130 are in contact with the surfaces of two intersecting steel bar units 21, the current can be transmitted through the first welding head 120 to one of the steel bar units 21, and then flow through the welding point 22 where the two steel bar units 21 are in contact to the other steel bar unit 21, and finally flow back to the power supply unit through the second welding head 130 and the second conductive connector, thereby forming a closed resistance welding circuit. According to the principle of resistance welding, the contact resistance of the two steel rebars 21 at the welding point 22 is much greater than the resistance of the steel rebar body and the weld head. When the current flows through this contact resistance, it will generate concentrated resistance heat according to Joule's law, causing the temperature at the welding point 22 to rise rapidly and the surface of the steel rebar to reach a local melting state. Under the pressing action of the first arc surface 121 and the second arc surface 131, the two steel rebars 21 achieve metallurgical bonding at the welding point 22. After the heat cools down, the two steel rebars 21 can form a strong welded joint, completing the welding operation.

[0042] Therefore, the welding device 10 of this application embodiment achieves rapid positioning, stable power supply and uniform welding of the welding point 22 through the coordinated cooperation of various components, effectively simplifying the welding operation steps, reducing the difficulty of manual operation, ensuring the stability of welding quality and significantly improving welding construction efficiency.

[0043] See Figure 1 and Figure 2 In some embodiments, the first welding head 120 and the second welding head 130 are integral structures.

[0044] It should be noted that the integrated structure mentioned here is not a fixed, inseparable connection between the first welding head 120 and the second welding head 130, nor is it impossible to disassemble, repair, or replace them according to actual usage needs. Rather, the first welding head 120 and the second welding head 130 are integrated into a single structure. Their relative positions and height differences can be pre-fixed in a preset state by the same mounting bracket 110 to accommodate the welding positioning of intersecting steel bar units 21. This ensures that the first arc-shaped surface 121 and the second arc-shaped surface 131 can accurately correspond to the lower and upper steel bar units 21 without the need for additional adjustments to their relative positions during operation. This design eliminates the need for two operators to separately operate the first welding head 120 and the second welding head 130, or for both hands to operate the first welding head 120 and the second welding head 130 separately. As a result, the welding device 10 can be operated by a single person with one hand, simplifying the operation process, reducing the labor intensity of the operator, and avoiding positioning deviations caused by separately operating the two welding heads. This further improves the positioning accuracy of the welding point 22 and the efficiency of the welding operation, ensuring the stability and reliability of the welding process.

[0045] See Figure 1 and Figure 2 In some embodiments, the first welding head 120 and the second welding head 130 are offset in the first direction X.

[0046] The staggered arrangement here refers to the fact that the orthographic projections of the first welding head 120 and the second welding head 130 in the first direction X are at least partially offset. This arrangement effectively avoids interference between the first welding head 120 and the second welding head 130 during positioning, facilitating precise positioning of the corresponding steel rebar unit 21 by the welding assembly. Specifically, during the positioning operation, the operator can insert the first arc-shaped surface 121 of the first welding head 120 between the lower steel rebar unit 21 and the construction base surface to complete the lifting and support. At the same time, when the welding device 10 is rotated, the second arc-shaped surface 131 of the second welding head 130 can smoothly fit against the top of the upper steel rebar unit 21. This staggered design not only ensures the smooth realization of the positioning function of each welding head, but also further improves the convenience of the positioning operation, provides a reliable guarantee for subsequent stable welding, simplifies the operation process, and reduces the difficulty of manual operation.

[0047] In other words, if the first welding head 120 and the second welding head 130 are aligned in the first direction X, the two welding heads are likely to block each other and interfere during the positioning process. The first arc-shaped surface 121 of the first welding head 120 will have difficulty extending smoothly between the lower steel bar unit 21 and the construction base to complete the lifting support, which is not conducive to the accurate positioning of the welding assembly on the steel bar unit 21 and will lead to obstruction of the positioning operation.

[0048] See Figure 1 and Figure 2 In some embodiments, the first welding head 120 is arranged in pairs and symmetrically distributed on both sides of the second welding head 130 in the second direction Y, which intersects with the first direction X.

[0049] The second direction Y can be understood as the length direction of the steel bar unit 21 corresponding to the first weld head 120.

[0050] It should be noted that the paired and symmetrically distributed arrangement allows for more even force distribution on both sides of the lower rebar unit 21 in the second direction Y when supporting and positioning it, effectively improving the support stability and positioning accuracy of the rebar unit 21 during welding. Simultaneously, the symmetrically distributed first welding head 120 and second welding head 130 work together to further reduce the probability of motion interference between the welding heads during positioning operations, reserving sufficient operating space for the first arc-shaped surface 121 to extend into the lower rebar unit 21 and the construction base surface. In actual positioning, the paired first welding head 120 can simultaneously lift and support the lower rebar unit 21, and in conjunction with the rotation of the welding device 10, the second welding head 130 smoothly and steadily engages with the upper rebar unit 21. This ensures continuous and reliable positioning operations and significantly improves the overall smoothness of the welding operation, better enabling rapid and stable welding of intersecting rebar units 21.

[0051] See Figure 1 and Figure 2 In some embodiments, the mounting bracket 110 includes a pair of insulating connectors 111, each insulating connector 111 having a first end 111a and a second end 111b opposite each other in a first direction X, a first welding head 120 being connected to the first end 111a and a second welding head 130 being connected to the second end 111b.

[0052] Understandably, the insulating connector 111 is made of a material with excellent insulation properties, which can effectively isolate the first welding head 120 and the second welding head 130, prevent the formation of a current path between them, ensure that the first welding head 120 and the second welding head 130 are insulated from each other, avoid problems such as damage to the welding device 10 and welding interruption caused by short circuit of the welding head during the welding process, and ensure the safety and stability of the welding operation.

[0053] Optionally, the insulating connector 111 can be a rod-shaped structure, a column-shaped structure, a plate-shaped structure, etc., to ensure a stable connection between the first welding head 120 and the second welding head 130. The insulating connector 111 can be made of insulating plastic material, such as polyvinyl chloride, polypropylene, etc.

[0054] Among them, at least two pairs of insulating connectors 111 have different extension lengths in the first direction X, and the first end 111a of the insulating connector 111 is detachably connected to the first welding head 120, and the second end 111b is detachably connected to the second welding head 130.

[0055] In practice, by selecting insulating connectors 111 with different extension lengths for combination and installation, the height difference between the first welding head 120 and the second welding head 130 in the first direction X can be flexibly adjusted, thereby adjusting the height difference between them in the first direction X to adapt to the welding requirements of steel bar units 21 of different specifications. At the same time, the first end 111a of the insulating connector 111 is detachably connected to the first welding head 120, and the second end 111b is detachably connected to the second welding head 130. This detachable design allows the height of the installation cavity to be set according to the specifications of the steel bar. Operators can easily replace insulating connectors 111 with different extension lengths according to the actual size of the steel bar unit 21 in construction without replacing the whole unit. This reduces the cost of use and improves the adaptability and practicality of the welding device 10. It also facilitates the individual inspection and replacement of the first welding head 120, the second welding head 130, and the insulating connector 111, further ensuring the reliability of welding positioning.

[0056] For example, one of the first welding head 120 and the insulating connector 111 has a screw hole and the other has an external thread; one of the second welding head 130 and the insulating connector 111 has a screw hole and the other has an external thread. This configuration achieves a detachable connection while ensuring a secure connection between the first welding head 120, the second welding head 130, and the insulating connector 111, guaranteeing the structural strength of the connection points and effectively resisting vibration and stress during use, preventing the welding heads from loosening or falling off the insulating connector 111.

[0057] In some alternative embodiments, the paired second ends 111b extend toward each other in the second direction Y to connect to opposite sides of the second welding head 130 in the second direction Y. The extension lengths of the second ends 111b of at least two pairs of insulating connectors 111 in the second direction Y are different. The first end 111a is detachably connected to the first welding head 120, and the second end 111b is detachably connected to the second welding head 130.

[0058] The paired second ends 111b extend towards each other in the second direction Y, enabling the second welding head 130 to form a stable clamping connection with the insulating connector 111. This ensures that the second welding head 130 is subjected to uniform force during welding, preventing wobbling or displacement due to unstable connection, and ensuring close contact between the second welding head 130 and the upper reinforcing bar unit 21, providing reliable support for welding positioning. The second ends 111b of at least two pairs of insulating connectors 111 have different extension lengths in the second direction Y. By selecting insulating connectors 111 with different extension lengths for combination, the distance between the paired first welding heads 120 in the second direction Y can be adjusted to accommodate different extension lengths of the lower reinforcing bar unit 21. The longer the extension length of the lower reinforcing bar unit 21, the larger the spacing between the paired first welding heads 120 needs to be adjusted accordingly, achieving stable support and precise positioning for the lower reinforcing bar unit 21, and meeting the welding requirements of intersecting reinforcing bar units 21 of different specifications. The first end 111a is detachably connected to the first welding head 120, and the second end 111b is detachably connected to the second welding head 130. This allows operators to easily replace the insulating connectors 111 with different extension lengths according to construction needs, and also facilitates individual inspection and maintenance of components, improving the flexibility of the device while reducing operating costs. Furthermore, the spacing between the paired first welding heads 120 in the second direction Y can be set to be greater than the diameter of the steel bar unit 21, thus avoiding jamming when the steel bar unit 21 cannot be placed or positioned smoothly due to insufficient spacing, further improving the convenience of positioning operations.

[0059] It should be noted that during use, the orthogonal projections of the first welding head 120 and the second welding head 130 in the first direction X are configured to be staggered from the welding point 22, which ensures the effective transfer of welding heat and welding quality, while also making it easier for operators to observe the status of the welding point 22 and adjust the operation in a timely manner, further improving the reliability and safety of the welding operation.

[0060] See Figure 1 and Figure 2 In some embodiments, the first arcuate surface 121 is recessed in a direction away from the second arcuate surface 131, and the second arcuate surface 131 is also recessed in a direction away from the first arcuate surface 121. The axis of the first arcuate surface 121 and the axis of the second arcuate surface 131 are spatially intersecting.

[0061] This design allows the first arc-shaped surface 121 to fit tightly against the outer periphery of the lower reinforcing bar unit 21, and the second arc-shaped surface 131 to fit firmly against the outer periphery of the upper reinforcing bar unit 21. This creates a bidirectional limiting effect on the two intersecting reinforcing bar units 21, effectively preventing the reinforcing bar units 21 from shifting, sliding, or deviating due to vibration, external force, or current during welding operations. This provides a stable structural foundation for subsequent welding positioning and welding operations.

[0062] The axis of the first arc-shaped surface 121 and the axis of the second arc-shaped surface 131 are spatially intersecting. This means that the central axes of the two arc-shaped surfaces are not coplanar or parallel, and they intersect at a point. They do not intersect in the same plane, but rather form a spatial intersection. This spatial intersection arrangement matches the actual intersection state of the two steel reinforcement units 21, ensuring that the two arc-shaped surfaces make surface contact with their respective steel reinforcement units 21. This improves the contact stability between the weld head and the steel reinforcement unit 21, and ensures uniform current transmission at the contact point. It avoids uneven resistance heating at the welding point 22 due to poor contact and uneven conductivity, thus preventing welding defects such as weak welds and weld cracks. For example, the axis of the first arc-shaped surface 121 and the axis of the second arc-shaped surface 131 are spatially perpendicular to each other to accommodate the commonly seen perpendicularly intersecting arrangement of two steel reinforcement units 21 in actual construction. This ensures the fit between the arc-shaped surfaces and the outer circumference of the steel reinforcement unit 21, further improving the limiting effect and the uniformity of conductivity.

[0063] See Figure 1 and Figure 2 In some embodiments, the welding assembly further includes a gripper 140 connected to the side of the second welding head 130 opposite to the second arcuate surface 131, and at least a portion of the power supply assembly is integrally formed with the gripper 140.

[0064] Optionally, the gripper 140 can be a rod-shaped structure. By connecting the gripper 140 to the side of the second welding head 130 facing away from the second arc-shaped surface 131, the gripper 140 can avoid obstructing the contact area between the second arc-shaped surface 131 and the upper reinforcing bar unit 21. Simultaneously, when the operator holds the gripper 140, they can precisely control the position of the second welding head 130, facilitating adjustments to the angle and posture of the welding device 10 and improving the convenience of positioning and welding operations. By setting the gripper 140 as a rod-shaped structure, it allows the operator to hold it securely for extended periods, ensuring the stability of the welding operation.

[0065] At least some of the power supply components and the gripper 140 are integrated into a single structure, which effectively simplifies the overall structure of the welding assembly, achieves a compact design, avoids the problems of bulkiness and complicated connections caused by separating the power supply components and the gripper 140, and improves the structural stability of the welding assembly. This design is not only convenient for operators to carry and hold, but also simplifies the operation process, reduces auxiliary steps in the construction process, and effectively improves ease of use and construction efficiency.

[0066] Optionally, the gripper 140 may be made of insulating material or have an external insulating material layer, thereby effectively isolating the current conducted from the power supply component to the gripper 140, preventing the operator from being electrocuted when holding the gripper 140, and avoiding current leakage from affecting the stability of the power supply, thus ensuring the safety and reliability of the welding operation.

[0067] See Figure 1 and Figure 2 In some embodiments, the power supply assembly further includes a power switch communicatively connected to the power supply element, the power switch being embedded at the end of the grip 140 away from the second welding head 130, and the power supply element being embedded in the grip 140.

[0068] The power supply component is embedded inside the gripper 140, making full use of the internal space of the gripper 140 and further optimizing the overall compactness of the welding device 10. This avoids problems such as easy damage and additional space occupation caused by exposed power supply components, while achieving integrated operation of the power supply component and the gripper 140. The power switch is communicatively connected to the power supply component, enabling precise control of the power supply circuit. This ensures that operators can flexibly turn the power supply on or off by manipulating the power switch, preventing accidental power supply or operation during welding and ensuring the safety of the welding operation. The power switch is embedded at the end of the gripper 140 away from the second welding head 130. This position conforms to operating habits. When the operator holds the gripper 140 for welding positioning and operation, they can easily reach the power switch without additional hand position adjustments, enabling convenient control of power supply start and stop, simplifying the operation process, and further improving the ease of use and construction efficiency of the device.

[0069] See Figure 4 Based on the above embodiments, this application provides a welding process for reinforced steel structures, including: S10: Provide a welding device 10 for steel reinforcement structures as provided in any of the above embodiments, which supports one of the steel reinforcement units 21 by a first welding head 120 and presses a second welding head 130 onto another intersecting steel reinforcement unit 21, so that the two steel reinforcement units 21 abut against each other at the welding point 22.

[0070] In practice, the operator can hold the gripper 140 of the welding device 10 and precisely control the device to move it to the construction position. The first arc-shaped surface 121 of the first welding head 120 is used to support one of the individual steel bars 21, maintaining its stability. Then, the device angle is adjusted so that the second arc-shaped surface 131 of the second welding head 130 is pressed against another intersecting steel bar 21. The limiting effect of the first and second arc-shaped surfaces 121 ensures that the intersection of the two steel bars 21 is aligned with the preset welding point 22, and the pressure causes them to fit tightly together at the welding point 22. Throughout the operation, thanks to the structural advantages of the welding device 10, the positioning and contact of the steel bars 21 can be completed without additional auxiliary tools, ensuring tight contact at the welding point 22. This provides reliable assurance for subsequent power welding, resistance heat generation, and welding quality, while simplifying the operation process and improving construction convenience.

[0071] S20: The power supply component is turned on, and the welding device 10 forms a resistance welding circuit acting on the welding point 22 to generate resistance heat so that the two steel bar units 21 melt at the welding point 22.

[0072] In practice, the operator can conveniently control the power supply component to be turned on by using a power switch embedded in the end of the gripper 140 away from the second welding head 130. After the power supply component is turned on, due to the contact resistance at the welding point 22, uniform resistance heat will be generated when the current passes through. The heat will continue to accumulate and concentrate on the welding point 22, gradually raising the temperature of the contact area between the two steel bar units 21 until the area reaches a melting state.

[0073] S30: Maintain the preset duration and apply pressure to the preset pressure value through the second welding head 130 to complete the welding.

[0074] It should be noted that the purpose of maintaining the preset time is to ensure that the molten steel bar individual 21 at the welding point 22 can be fully fused, to avoid insufficient fusion due to rapid heat loss, and thus to prevent welding defects such as loose welds and weak bonding. This provides sufficient solidification time for the molten steel bar individual 21 to ensure welding strength.

[0075] Simultaneously, while maintaining the preset time, pressure is applied to the welding point 22 of the two steel rebar units 21 to a preset pressure value through the second welding head 130. This pressure ensures that the molten metal from the two steel rebar units 21 fully contacts and fuses tightly, improving the density and reliability of the weld joint. The operator holds the gripper 140, keeping the second welding head 130 continuously pressing against the upper steel rebar unit 21 to ensure stable and uniform pressure. Throughout the process, pressure application and time are synchronized, ensuring both full fusion of the welding point 22 and the quality of the weld. After the preset time ends and the pressure stabilizes, the power supply component is disconnected, completing the entire welding process and forming a stable connection structure between the two intersecting steel rebar units 21, meeting the strength requirements of steel rebar construction.

[0076] In some embodiments, before step S30: maintaining a preset duration and applying pressure to a preset pressure value through the second welding head 130 to complete the welding, the method further includes: S21: Determine at least one of the preset duration and preset pressure value based on the target information.

[0077] The target information includes at least one of the following: the diameter, material, welding strength, and welding current of the steel bar unit 21.

[0078] In practice, changes in the target information will correspondingly adjust the preset duration and preset pressure values. The larger the diameter of the steel bar 21, the larger the melting volume of its welding point 22, and the greater the required preset pressure value. At the same time, the preset duration needs to be extended to ensure that the molten metal fully fuses and solidifies densely, avoiding loose weld joints. Different materials have different melting points and thermal conductivity. For materials with higher melting points and better thermal conductivity, the preset duration needs to be extended and the preset pressure appropriately increased to ensure that the welding point 22 has sufficient heat and complete solidification. Conversely, the duration can be shortened and the pressure reduced. The higher the required welding strength, the more the preset pressure needs to be increased to compress the welding point 22, and the longer the preset duration needs to be extended to ensure sufficient fusion, thereby improving the welding strength. The larger the welding current, the more resistance heat is generated, and the faster the welding point 22 melts. The preset duration can be shortened appropriately, and the preset pressure can be slightly adjusted to reduce it to avoid excessive heat causing weld joint burn-out and deformation.

[0079] For example, if the steel bar 21 to be welded has a large diameter and is made of high-melting-point steel, compared to ordinary steel with a smaller diameter and lower melting point, the preset pressure needs to be increased and the preset time extended to ensure that the molten metal at the welding point 22 is fully fused and solidified. By determining the preset time and preset pressure values ​​based on the target information, the welding requirements of different construction scenarios can be flexibly adapted, improving the practicality and reliability of the welding process.

[0080] Optionally, the preset duration can be any value between 2s and 5s, including the two values ​​of 2s and 5s, and the preset pressure value can be any value between 0.05MPa and 0.2MPa, including the two values ​​of 0.05MPa and 0.2MPa.

[0081] For example, when the diameter of the welded unit is 20mm, the material is HRB400E threaded steel, the welding strength requirement is not less than the strength of the steel bar itself, and the welding current is a conventional welding current suitable for this specification of steel bar, the preset time can be set to 3.5s, and the preset pressure value can be set between 0.1MPa and 0.15MPa. Specific settings can be made in accordance with the "Code for Welding and Acceptance of Reinforcing Steel Bars" (JGJ 18—2012) and the "Code for Acceptance of Construction Quality of Concrete Structures" (GB 50204—2015), etc., with the aim of meeting the acceptance requirements.

[0082] In some embodiments, the welding device 10 may be equipped with a pressure sensor and a timing device. The pressure sensor is embedded in the connection between the second welding head 130 and the gripper 140, or directly integrated into the second welding head 130. It can sense the pressure value manually applied to the steel bar 21 by the operator in real time and convert it into an electrical signal, which is then transmitted to an external control unit or display module. This allows the operator to intuitively confirm whether the current pressure is within the preset range, avoiding weak welding due to insufficient pressure or deformation of the steel bar 21 due to excessive pressure. The timing device is communicatively connected to the power supply component and is used to accurately record the welding duration after power is turned on, i.e., the entire process from the start of the power supply component, the formation of the conductive circuit, and the generation of resistance heat, to the end of the preset time. The timing device may be a built-in timer or an external timing module to ensure that the welding duration strictly conforms to the preset value determined according to the target information, ensuring that the steel bar 21 at the welding point 22 can be fully melted, fused, and solidified.

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A welding apparatus for a reinforced steel structure, the reinforced steel structure comprising a plurality of steel reinforcement units (21), at least two of the steel reinforcement units (21) being arranged intersecting to form welding points (22), characterized in that, The welding apparatus (10) includes: The welding assembly includes a mounting frame (110) and a first welding head (120) and a second welding head (130) insulated from each other on the mounting frame (110). The first welding head (120) and the second welding head (130) have a height difference in a first direction (X) and form a mounting cavity to accommodate two steel bar units (21) that intersect to form the welding point (22). The first welding head (120) has a first arcuate surface (121), and the second welding head (130) has a second arcuate surface (131). The first arcuate surface (121) contacts one of the two steel bar units (21) that intersect to form the welding point (22), and the second arcuate surface (131) contacts the other of the two steel bar units (21) that intersect to form the welding point (22). The power supply assembly includes a power supply component and a first conductive connector and a second conductive connector connected to the power supply component. The first conductive connector is connected to the first welding head (120), and the second conductive connector is connected to the second welding head (130) to form a resistance welding circuit acting on the welding point (22).

2. The welding device for reinforced concrete structures according to claim 1, characterized in that, The first welding head (120) and the second welding head (130) are integral structures.

3. The welding device (10) for reinforced concrete structures according to claim 1, characterized in that, The first welding head (120) and the second welding head (130) are offset in the first direction (X).

4. The welding apparatus for reinforced concrete structures according to claim 3, characterized in that, The first welding head (120) is arranged in pairs and symmetrically distributed on both sides of the second welding head (130) in the second direction (Y), which intersects with the first direction (X).

5. The welding apparatus for reinforced concrete structures according to claim 3, characterized in that, The mounting bracket (110) includes a pair of insulating connectors (111), each of the insulating connectors (111) having a first end (111a) and a second end (111b) opposite each other in a first direction (X), the first welding head (120) being connected to the first end (111a) and the second welding head (130) being connected to the second end (111b). Among them, at least two pairs of insulating connectors (111) have different extension lengths in the first direction (X), and the first end (111a) of the insulating connector (111) is detachably connected to the first welding head (120), and the second end (111b) is detachably connected to the second welding head (130). And / or, the paired second ends (111b) extend toward each other in the second direction (Y) to connect to the opposite sides of the second welding head (130) in the second direction (Y), the extension lengths of the second ends (111b) of at least two pairs of the insulating connectors (111) in the second direction (Y) are different, the first end (111a) is detachably connected to the first welding head (120), and the second end (111b) is detachably connected to the second welding head (130).

6. The welding apparatus for reinforced concrete structures according to claim 1, characterized in that, The first arc-shaped surface (121) is recessed in a direction away from the second arc-shaped surface (131), and the second arc-shaped surface (131) is recessed in a direction away from the first arc-shaped surface (121); The axis of the first arc-shaped surface (121) and the axis of the second arc-shaped surface (131) are spatially intersected.

7. The welding apparatus for reinforced concrete structures according to claim 1, characterized in that, The welding assembly further includes a gripper (140) connected to the side of the second welding head (130) opposite to the second arcuate surface (131); At least a portion of the power supply component is integrally formed with the grip (140).

8. The welding apparatus for reinforced concrete structures according to claim 7, characterized in that, The power supply assembly also includes a power supply switch that is communicatively connected to the power supply component. The power supply switch is embedded at one end of the grip (140) away from the second welding head (130). The power supply component is embedded in the grip (140).

9. A welding process for reinforced concrete structures, characterized in that, include: A welding apparatus (10) for a steel reinforcement structure as described in any one of claims 1 to 8 is provided, wherein one of the steel reinforcement units (21) is supported by a first welding head (120), and a second welding head (130) is pressed against another intersecting steel reinforcement unit (21), such that the two steel reinforcement units (21) abut against each other at the welding point (22); When the power supply component is turned on, the welding device (10) forms a resistance welding circuit acting on the welding point (22) to generate resistance heat so that the two steel bar units (21) melt at the welding point (22). Maintain the preset duration and apply pressure to the preset pressure value through the second welding head (130) to complete the welding.

10. The welding process for reinforced concrete structures according to claim 9, characterized in that, The procedure includes, prior to the step of maintaining the welding for a preset duration and applying pressure to a preset pressure value via the second welding head (130) to complete the welding: Determine at least one of the preset duration and the preset pressure value based on the target information; The target information includes at least one of the diameter, material, welding strength, and welding current of the steel bar (21).

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