Steel structure welding deformation correction device and correction method thereof

Abstract

The application discloses a steel structure welding deformation correction device and a correction method thereof, and relates to the technical field of steel structure processing. The device comprises a portal frame, an electric roller, a web guide structure, a laser displacement detection light curtain, an inner-outer matched correction mechanism, a lifting adjusting mechanism, a matched PLC electric control system and a hydraulic servo control system; the web guide structure with double distance sensors is used to realize accurate centering of H-shaped steel, the laser displacement detection light curtain is used to complete online detection of the deformation of the whole width of the wing plate, the inner-outer correction wheels arranged in a staggered mode are used to form three-point bending correction force, and the electric roller is used to drive the steel to move back and forth, so that continuous closed-loop correction is realized. The correction method covers the whole process of centering positioning, deformation detection, mechanism alignment, reciprocating correction and qualified verification, and can be adapted to H-shaped steels of different specifications. The steel structure welding deformation correction device and the correction method thereof can solve the technical problems of low correction efficiency, poor precision and low automation degree in the prior art.

Description

Technical Field

[0001] This invention relates to the field of steel structure processing technology, specifically to a steel structure welding deformation correction device and its correction method. Background Technology

[0002] H-beams, as a high-efficiency and economical structural steel profile, are widely used in steel structure projects such as industrial plants, bridges, and high-rise buildings. During the welding and manufacturing process of H-beams, uneven heat input, cooling contraction, and residual stress release can easily lead to welding deformation problems such as flange bending and web twisting. These deformations directly affect the dimensional accuracy, assembly quality, and load-bearing capacity of the structural components, and in severe cases, can even lead to product scrap.

[0003] Currently, the following methods are mainly used to correct welding deformation of H-beams: First, flame straightening, which uses local heating to induce thermoplastic deformation in the steel. This method is complex to operate, energy-intensive, highly dependent on the experience of the operators, and can easily lead to a decline in material properties. Second, mechanical pressure straightening, which uses a press to apply reverse pressure to the deformed part for straightening. However, existing equipment is mostly single-point or segmented operation, which makes it difficult to achieve continuous automated straightening. Moreover, there is a lack of real-time detection and feedback control of deformation during the straightening process, making it difficult to guarantee the accuracy and consistency of the straightening.

[0004] Therefore, developing an H-beam welding deformation correction device capable of automatic detection, precise positioning, and continuous correction is of great significance for improving the production efficiency and quality of steel structures. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a steel structure welding deformation correction device and its correction method, in order to solve the technical problems of low correction efficiency, poor accuracy, and low degree of automation in existing technologies.

[0006] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a steel structure welding deformation correction device, comprising a frame assembly, wherein the frame assembly includes two parallel load-bearing columns, and a crossbeam is fixedly connected to the top of the two load-bearing columns. Two support boxes are provided between the two load-bearing columns. The two support boxes are arranged close to the load-bearing columns on the corresponding sides. The top of the support box is rotatably connected to an electric roller. A first lifting platform and a second lifting platform are provided between the two support boxes. There are two first lifting platforms. The second lifting platform is located between the two first lifting platforms and corresponds to the middle position of the crossbeam. A third lifting platform is vertically fixedly connected to the top of the crossbeam at the position corresponding to the second lifting platform. The top of the first lifting platform is provided with a web plate guide structure, the top of the web plate guide structure is provided with a first ranging sensor, and the two sides of the web plate guide structure are provided with second ranging sensors. The inner sides of both load-bearing columns are equipped with lifting and adjusting mechanisms, and laser displacement detection light curtains are vertically fixed on both sides of the lifting and adjusting mechanisms via brackets. The top of the second lifting platform is fixedly provided with a first internal correction mechanism, and the bottom of the third lifting platform is fixedly provided with a second internal correction mechanism. The top of the first internal correction mechanism is provided with a third distance sensor, and the bottom of the second internal correction mechanism is provided with a fourth distance sensor. The lifting adjustment mechanism is provided with a first external correction mechanism corresponding to the first internal correction mechanism and a second external correction mechanism corresponding to the second internal correction mechanism on one side. The lifting adjustment mechanism adjusts the first outer correction mechanism and the first inner correction mechanism to be at the same height, and the second inner correction mechanism and the second outer correction mechanism to be at the same height, based on the measurement results of the third and fourth distance sensors. The axis of the outer correction wheel is located at the corresponding position of the center of the two adjacent inner correction wheels.

[0007] It also includes an electrical control system and a hydraulic control system. The electrical control system is electrically connected to all sensors, electric rollers, and motors. The hydraulic control system is connected to the hydraulic actuators of the first lifting platform, the second lifting platform, the third lifting platform, the lifting adjustment mechanism, the first external correction mechanism, the first internal correction mechanism, the second internal correction mechanism, and the second external correction mechanism.

[0008] Furthermore, the web plate guide structure includes a housing, symmetrical lead screws, and a motor. The symmetrical lead screws are rotatably connected inside the housing, and the motor is fixed inside the housing. A synchronous pulley is fixed in the middle of the symmetrical lead screws, and the motor is connected to the synchronous pulleys via a belt. A bracket is symmetrically threaded on the surface of the symmetrical lead screws, and one end of the bracket extends to the outside of the housing and is fixedly connected to a guide wheel frame. A guide wheel is rotatably connected to the surface of the guide wheel frame.

[0009] Furthermore, the lifting and adjusting mechanism includes a fixed housing, a first hydraulic rod is vertically fixedly connected to the bottom of the inner wall of the fixed housing, a second hydraulic rod is vertically fixedly connected to the top of the inner wall of the fixed housing, and a guide rail is provided on the inner wall of the fixed housing; both the first external correction mechanism and the second external correction mechanism are slidably connected to the guide rail, the working end of the first hydraulic rod is fixedly connected to the first external correction mechanism, and the working end of the second hydraulic rod is fixedly connected to the second external correction mechanism.

[0010] Furthermore, the first external correction mechanism includes a lifting housing, a telescopic housing is horizontally slidably connected to one side of the lifting housing, an external correction wheel frame is fixedly connected to one end of the telescopic housing, an external correction wheel is rotatably connected to one side of the external correction wheel frame, and a third hydraulic rod is horizontally arranged between the lifting housing and the telescopic housing; the structure of the second external correction mechanism is completely identical to that of the first external correction mechanism.

[0011] Furthermore, the first internal correction mechanism includes a fixed cylinder, with telescopic cylinders symmetrically slidably connected to both ends of the fixed cylinder. An internal correction wheel frame is fixedly connected to one end of the telescopic cylinder, and an internal correction wheel is rotatably connected to one side of the internal correction wheel frame. A fourth hydraulic rod is horizontally arranged between the fixed cylinder and the telescopic cylinders on both sides. The structure of the second internal correction mechanism is completely identical to that of the first internal correction mechanism.

[0012] Furthermore, the electronic control system includes a core control unit, a signal acquisition module, a motor drive module, a human-machine interaction module, and a safety protection module. The core control unit adopts an industrial-grade programmable logic controller. The signal acquisition module is electrically connected to all detection elements. The motor drive module is electrically connected to the drive motor of the electric roller and the motor of the web guide structure, respectively. The human-machine interaction module adopts an industrial touch screen that is communicatively connected to the core control unit. The safety protection module includes an emergency stop button, an audible and visual alarm, and limit sensors.

[0013] A method for correcting welding deformation in steel structures, implemented using the aforementioned steel structure welding deformation correction device, includes the following steps: S1 Loading and Centering Positioning: The H-beam to be straightened is placed on the electric roller. The electrical control system controls the first lifting platform to lift the web guide structure to the set height according to the specifications of the H-beam. The positioning is fed back by the first distance sensor. The centering positioning of the H-beam is completed by using the web guide structure. S2 Deformation Detection and Data Processing: The electric roller is started to drive the H-beam to move at a constant speed along its length. The laser displacement detection light curtains on both sides continuously scan the entire width of the H-beam flange to collect the distance data on the flange surface. The electronic control system performs fitting calculations on the collected data to obtain the bending deformation amount, deformation position, deformation curvature and deformation direction of the flange. At the same time, the axial coordinates of the deformation area are locked by the position encoder. S3 Alignment Mechanism: Based on the H-beam specifications and deformation detection data, the electronic control system controls the second and third lifting platforms to move the first and second inner alignment mechanisms to the corresponding heights of the wing plates, respectively, and uses the third and fourth distance sensors to provide feedback on positioning; at the same time, it controls the lifting adjustment mechanism to drive the first outer alignment mechanism to align with the first inner alignment mechanism and the second outer alignment mechanism to align with the second inner alignment mechanism. S4 Continuous Reciprocating Correction: The electronic control system controls the extension of the fourth hydraulic rod of the inner correction mechanism, so that the inner correction wheel presses against the inner surface of the wing plate; controls the extension of the third hydraulic rod of the outer correction mechanism, so that the outer correction wheel presses against the outer surface of the wing plate, and forms a three-point bending correction force through the staggered arrangement of the inner and outer correction wheels; controls the electric roller to drive the H-beam to move back and forth along the length direction to continuously correct the deformed area. During the correction process, the correction force is fed back in real time through the pressure sensor to realize closed-loop adjustment. S5 Correction Verification and Material Cutting: After a single correction is completed, the laser displacement detection light curtain scans the H-beam steel wing plate again to detect the full width. If the deformation of the wing plate is within the preset allowable tolerance range, the correction is completed, all mechanisms are reset, and material cutting is performed. If the deformation still exceeds the tolerance, steps S4-S5 are repeated until the test results meet the tolerance requirements.

[0014] Furthermore, in step S4, the electronic control system dynamically adjusts the output pressure of the hydraulic system and the extension of the correction wheel according to the deformation amount and type of the wing plate. For wing plates that bend outward, the clamping force of the outer correction wheel is increased; for wing plates that bend inward, the clamping force of the inner correction wheel is increased.

[0015] Further, in step S2, the electronic control system filters the collected distance data, fits and generates the surface profile curve of the wing plate, compares the profile curve with the standard straight line, calculates the bending deformation amount and deformation curvature of the wing plate, and determines whether the deformation direction is inward bending or outward bending.

[0016] (III) Beneficial Effects This invention provides a steel structure welding deformation correction device and method, which has the following beneficial effects: 1. Fully automated detection and correction: The wing plate is continuously scanned across the entire width using a laser displacement detection light curtain, enabling online automatic detection and quantitative analysis of deformation. This eliminates the need for manual measurement and judgment, improving detection efficiency and accuracy.

[0017] 2. Precise positioning and centering: Multiple sets of distance measuring sensors and web plate guiding structure are used to realize the automatic centering of H-beams and the precise positioning of the correction mechanism, providing a reliable position reference for precise correction.

[0018] 3. Continuous reciprocating correction: Through the staggered arrangement of inner and outer correction wheels and the reciprocating movement of H-beams, continuous three-point bending correction of the deformation area is achieved, which has high correction efficiency and can be flexibly adjusted for different deformation positions.

[0019] 4. Closed-loop feedback control: During the calibration process, the calibration force and deformation status are fed back in real time through pressure sensors and laser displacement detection light curtains. The electronic control system dynamically adjusts the calibration parameters to ensure calibration accuracy and consistency and avoid over- or under-calibration.

[0020] 5. High adaptability: With its lifting and adjusting mechanism and retractable correction wheel structure, it can adapt to H-beams of different specifications and sizes, meeting the correction needs of various product models. Attached Figure Description

[0021] Figure 1 This is a front view of the overall structure of the present invention; Figure 2 This is a right view of the overall structure of the present invention; Figure 3 This is a schematic diagram showing the location of the web guide structure of the present invention; Figure 4 This is a schematic diagram of the correction state of the present invention; Figure 5 This is a schematic diagram showing the distribution of the web plate guide structure and the first internal correction mechanism of the present invention; Figure 6 This is a schematic diagram of the lifting adjustment mechanism and the first external correction mechanism of the present invention.

[0022] In the diagram: 1-Load-bearing column, 2-Crossbeam, 3-Supporting box, 4-Electric roller, 5-First lifting platform, 6-Second lifting platform, 7-Third lifting platform, 8-Web plate guide structure, 81-Box, 82-Symmetrical lead screw, 83-Motor, 84-Synchronous pulley, 85-Bracket, 86-Guide wheel frame, 87-Guide wheel, 9-First ranging sensor, 10-Second ranging sensor, 11-Mounting bracket, 12-Laser displacement detection light curtain, 13-First internal correction mechanism, 131-Fixed cylinder, 132-Telescopic cylinder 133-Inner calibration wheel frame, 134-Inner calibration wheel, 135-Fourth hydraulic rod, 14-Second inner calibration mechanism, 15-Third distance sensor, 16-Fourth distance sensor, 17-Lifting adjustment mechanism, 171-Fixed housing, 172-First hydraulic rod, 173-Second hydraulic rod, 174-Guide rail, 18-First outer calibration mechanism, 181-Lifting housing, 182-Telescopic housing, 183-Outer calibration wheel frame, 184-Outer calibration wheel, 185-Third hydraulic rod, 19-Second outer calibration mechanism. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Example 1 This embodiment provides a steel structure welding deformation correction device, such as Figures 1-6 As shown, the device includes a frame assembly, which includes two parallel and vertically arranged load-bearing columns 1. The tops of the two load-bearing columns 1 are fixedly connected to horizontally arranged crossbeams 2, forming a portal frame structure to ensure the overall rigidity of the device.

[0025] Two support boxes 3 are installed between the two load-bearing columns 1. The two support boxes 3 are arranged close to the load-bearing columns 1 on the corresponding sides. The support boxes 3 are welded steel structure boxes, and the bottom is fixed to the equipment foundation by anchor bolts. The top of each support box 3 is rotatably connected to two sets of electric rollers 4 along the length of the H-beam. The rotation axis of the electric rollers 4 is perpendicular to the length of the H-beam. The two sets of electric rollers 4 on the same side are connected by a synchronous chain transmission mechanism to ensure synchronous rotation. The surface of the electric rollers 4 is covered with a wear-resistant rubber layer to support the lower flange of the H-beam and drive the H-beam to move back and forth along its length through friction, so as to avoid scratches on the surface of the H-beam.

[0026] A first lifting platform 5 and a second lifting platform 6 are fixedly installed on the equipment foundation between the two supporting boxes 3. There are two first lifting platforms 5, each located on one side close to the supporting box 3. The second lifting platform 6 is located between the two first lifting platforms 5, and is directly opposite the middle of the crossbeam 2. A third lifting platform 7 is vertically fixedly connected to the top of the crossbeam 2, directly opposite the second lifting platform 6. The working end of the third lifting platform 7 extends downwards to the bottom of the crossbeam 2. In this embodiment, the lifting stroke of the first lifting platform 5, the second lifting platform 6, and the third lifting platform covers H-beams with a web height of 200mm-1500mm, adapting to most engineering H-beam specifications.

[0027] The top of the first lifting platform 5 is fixedly equipped with a web guide structure 8, which is used to achieve the left-right centering positioning and axial movement guidance of the H-beam. Figure 5As shown, the web guide structure 8 includes a housing 81, a symmetrical lead screw 82, and a motor 83. The symmetrical lead screw 82 is rotatably connected to the inner cavity of the housing 81 via bearing seats at both ends. The left and right ends of the symmetrical lead screw 82 are provided with external threads in opposite directions. The motor 83 is a servo motor, fixed to the bottom of the inner cavity of the housing 81. A synchronous pulley 84 is fixed to the middle of the symmetrical lead screw 82. A drive pulley is fixed to the output shaft of the motor 83, and the drive pulley is connected to the synchronous pulley 84 via a synchronous belt. The symmetrical lead screw 8... 2. Symmetrically threaded sections at both ends are connected to C-shaped brackets 85. The top of the housing 81 is provided with a long groove corresponding to the bracket 85. The upper end of the bracket 85 extends through the groove to the outside of the housing 81 and is fixedly connected to a guide wheel frame 86. The surface of the guide wheel frame 86 is rotatably connected to a guide wheel 87 via a pin. The rotation axis of the guide wheel 87 is vertical, and its wheel surface is in contact with the inner surface of the H-beam flange, thereby achieving left and right limit of the H-beam without affecting the axial movement of the H-beam.

[0028] A first distance sensor 9 is installed at the center of the top of the box 81 of the web guide structure 8. The detection end of the first distance sensor 9 faces upward and is used to detect the distance between the web guide structure 8 and the bottom of the H-beam web. This ensures that the web guide structure 8 moves to a set position close to the web under the drive of the first lifting platform 5, avoiding collision with the web. A second distance sensor 10 is installed on each of the two guide wheel frames 86 of the web guide structure 8. The detection end of the second distance sensor 10 faces the direction of the H-beam wing plate and is used to detect the distance between the guide wheel 87 and the inner side of the wing plate. This ensures that the two guide wheels 87 are synchronously attached to the inner side of the wing plate under the drive of the motor 83, achieving precise centering of the H-beam.

[0029] Both load-bearing columns 1 have vertically fixed lifting and adjusting mechanisms 17 on their inner surfaces. Laser displacement detection light curtains 12 are vertically fixed to the left and right sides of the lifting and adjusting mechanisms 17 via mounting brackets 11. The detection surface of the laser displacement detection light curtains 12 faces the surface of the H-beam's flanges, and is used to perform full-width continuous scanning measurement of the surfaces of the flanges on both sides of the H-beam. In this embodiment, the laser displacement detection light curtains 12 are vertically arranged linear array multi-channel laser displacement light curtains. Each light curtain contains 64 equally spaced laser detection channels, with a detection accuracy of ±0.03mm and a sampling frequency of 200Hz. It can cover flanges with a height of up to 1500mm, achieving blind-spot-free detection. By detecting the real-time distance between the light curtain and the flange surface, the bending deformation parameters of the flange are obtained.

[0030] The top of the second lifting platform 6 is fixedly equipped with a first internal correction mechanism 13, which is used to tighten and correct the inner side of the lower flange of the H-beam. The bottom of the third lifting platform 7 is fixedly equipped with a second internal correction mechanism 14, which is used to tighten and correct the inner side of the upper flange of the H-beam. A third distance sensor 15 is set at the top center of the first internal correction mechanism 13, with the detection end of the third distance sensor 15 facing upward, for detecting the distance between the first internal correction mechanism 13 and the bottom of the web of the H-beam, thereby achieving the height positioning of the first internal correction mechanism 13. A fourth distance sensor 16 is set at the bottom center of the second internal correction mechanism 14, with the detection end of the fourth distance sensor 16 facing downward, for detecting the distance between the second internal correction mechanism 14 and the top of the web of the H-beam, thereby achieving the height positioning of the second internal correction mechanism 14.

[0031] The lifting and adjusting mechanism 17 is provided with a first outer correction mechanism 18 corresponding to the first inner correction mechanism 13 and a second outer correction mechanism 19 corresponding to the second inner correction mechanism 14 on the side facing the H-beam. The first outer correction mechanism 18 is used to tighten and correct the outer side of the lower flange of the H-beam, and the second outer correction mechanism 19 is used to tighten and correct the outer side of the upper flange of the H-beam. The lifting and adjusting mechanism 17 can adjust the first outer correction mechanism 18 and the first inner correction mechanism 13 to be at the same height, and the second inner correction mechanism 14 and the second outer correction mechanism 19 to be at the same height, according to the measurement results of the third distance sensor 15 and the fourth distance sensor 16. The axis of the outer correction wheel 184 is located at the center corresponding position of the two adjacent inner correction wheels 134. Through the staggered cooperation of the inner and outer correction mechanisms, a three-point bending correction force is formed to realize the continuous correction of the bending deformation of the H-beam flange.

[0032] like Figure 6 As shown, the lifting and adjusting mechanism 17 includes a fixed housing 171, which is vertically fixed to the inner surface of the load-bearing column 1. A first hydraulic rod 172 is vertically fixed to the bottom of the inner wall of the fixed housing 171, and a second hydraulic rod 173 is vertically fixed to the top of the inner wall of the fixed housing 171. Vertical guide rails 174 are provided on both sides of the inner wall of the fixed housing 171. The first external correction mechanism 18 and the second external correction mechanism 19 are slidably connected to the guide rails 174 through sliders. The working end of the first hydraulic rod 172 is fixedly connected to the bottom of the first external correction mechanism 18, and the working end of the second hydraulic rod 173 is fixedly connected to the top of the second external correction mechanism 19. The first external correction mechanism 18 and the second external correction mechanism 19 are driven to lift independently by the first hydraulic rod 172 and the second hydraulic rod 173 respectively, so as to achieve precise alignment with the corresponding internal correction mechanism. The alignment accuracy can reach ±0.1mm.

[0033] like Figure 6As shown, the first external correction mechanism 18 includes a lifting housing 181, which is slidably connected to the guide rail 174 via a slider. A telescopic housing 182 is horizontally slidably connected to the side of the lifting housing 181 away from the load-bearing column 1. An external correction wheel frame 183 is fixedly connected to the end of the telescopic housing 182 away from the lifting housing 181. An external correction wheel 184 is rotatably connected to one side of the external correction wheel frame 183 via a pin. The rotation axis of the external correction wheel 184 is parallel to the length direction of the H-beam. A third hydraulic rod 185 is horizontally arranged in the inner cavity of the lifting housing 181. The fixed end of the third hydraulic rod 185 is fixedly connected to the lifting housing 181, and the working end of the third hydraulic rod 185 is fixedly connected to the telescopic housing 182, used to drive the external correction wheel 184 to extend and retract horizontally, adjusting the magnitude of the correction force. The second external correction mechanism 19 has the same structure as the first external correction mechanism 18, and will not be described again here.

[0034] like Figure 5 As shown, the first inner correction mechanism 13 includes a fixed cylinder 131, which is horizontally fixed to the top of the second lifting platform 6. Telescopic cylinders 132 are symmetrically slidably connected to both ends of the fixed cylinder 131. An inner correction wheel frame 133 is fixedly connected to one end of the telescopic cylinder 132 away from the fixed cylinder 131. An inner correction wheel 134 is rotatably connected to one side of the inner correction wheel frame 133 via a pin. The rotation axis of the inner correction wheel 134 is parallel to the rotation axis of the outer correction wheel 184. Two fourth hydraulic rods 135 are horizontally arranged in the inner cavity of the fixed cylinder 131. The two fourth hydraulic rods 135 are symmetrically arranged. The fixed end of the fourth hydraulic rod 135 is fixedly connected to the middle of the fixed cylinder 131. The working end of the fourth hydraulic rod 135 is fixedly connected to the telescopic cylinder 132 on the corresponding side, which is used to drive the inner correction wheels 134 on both sides to extend and retract synchronously and press against the inner surface of the wing plate. The second inner correction mechanism 14 has the same structure as the first inner correction mechanism 13. The only difference is that the inner correction wheel 134 of the second inner correction mechanism 14 is arranged downwards to adapt to the inner correction of the upper flange of the H-beam. This will not be described in detail here.

[0035] The correction device in this embodiment also includes an electronic control system and a hydraulic control system. The electronic control system is electrically connected to all distance sensors, the laser displacement detection light curtain 12, the drive motor of the electric roller 4, the motor 83 of the web guide structure 8, and all limit sensors to realize signal acquisition and automated control of the entire device. The hydraulic control system is connected to all lifting platforms, the first hydraulic rod 172 and the second hydraulic rod 173 of the lifting adjustment mechanism 17, the third hydraulic rod 185 of the external correction mechanism, and the fourth hydraulic rod 135 of the internal correction mechanism to provide power and closed-loop control for each hydraulic actuator.

[0036] The electrical control system includes a core control unit, a signal acquisition module, a motor drive module, a human-machine interface module, and a safety protection module. The core control unit uses a Siemens S7-1214C industrial PLC, serving as the control core of the entire device. It is responsible for the acquisition, processing, logical judgment, and closed-loop control of all sensor signals and actuators. It also stores H-beam specifications, deformation detection data, calibration process parameters, and equipment operation logs. The signal acquisition module is electrically connected to all distance sensors, the laser displacement detection light curtain 12, position encoders, pressure sensors, and limit sensors, enabling real-time acquisition, filtering, and analog-to-digital conversion of detection signals. The motor drive module includes a frequency converter and a servo driver. The frequency converter is electrically connected to the drive motor of the electric roller 4, enabling speed adjustment and forward / reverse reciprocating control of the H-beam's axial movement. The movement speed can range from 0.5 m / min to 10 m / min. The servo drive is electrically connected to the motor 83 of the web guide structure 8, enabling precise rotation of the symmetrical lead screw 82 and controlling the synchronous opening and closing and centering positioning of the guide wheels 87 on both sides. The human-machine interface module uses a 10-inch industrial touch screen, which is connected to the core control unit via Profinet bus for operators to set parameters, monitor equipment status, visualize deformation data, query fault alarms, and export historical data. The safety protection module includes an emergency stop button, an audible and visual alarm, a safety circuit, and limit sensors. The emergency stop button is located on the operating side and at both ends of the equipment and is connected to the equipment safety circuit. In an emergency, it can directly cut off the power to all actuators. The audible and visual alarm is triggered when the equipment malfunctions, parameters exceed tolerances, or the mechanism overtravels. Limit sensors are set at the extreme positions of all lifting and telescopic mechanisms to achieve overtravel protection of the mechanism.

[0037] The hydraulic control system includes a hydraulic pump station assembly, a lifting control circuit, a calibration execution circuit, and a system protection circuit. The hydraulic pump station assembly includes an oil tank, an axial piston pump, a drive motor, a high-pressure filter, a return oil filter, a cooler, an accumulator, a proportional relief valve, and a pressure relay, providing stable hydraulic power to the entire hydraulic system. The system's rated pressure is 16 MPa. The proportional relief valve enables stepless adjustment of the system pressure, and the accumulator is used to stabilize the system pressure, compensate for oil circuit leaks, and provide emergency power. The lifting control circuit is connected to the first lifting platform 5, the second lifting platform 6, the third lifting platform 7, the first hydraulic rod 172, and the second hydraulic rod 173. Each lifting actuator is equipped with an independent solenoid directional valve, a two-way hydraulic lock, and a one-way throttle valve. The two-way hydraulic lock is used to lock the position of the actuator to prevent the mechanism from falling after a power failure, and the one-way throttle valve... The valve is used to smoothly adjust the lifting speed; the correction execution circuit is connected to the third hydraulic rod 185 and the fourth hydraulic rod 135 respectively. Each correction hydraulic actuator is equipped with an independent electro-hydraulic servo valve, pressure sensor and displacement sensor to realize dual closed-loop control of extension position and output correction force. The core control unit can dynamically adjust the servo valve opening and system pressure according to the deformation of the wing plate to accurately control the magnitude of the correction force and avoid under-correction or over-correction of the wing plate; the system protection circuit includes a level gauge, oil temperature sensor, pressure relay and safety valve. The level gauge and oil temperature sensor are located in the oil tank. When the oil temperature exceeds 55°C, the cooler is automatically started. When the liquid level is lower than the set lower limit, an alarm is triggered and the pump is stopped. The pressure relay is located on the high-pressure side of the system. When the pressure exceeds 18MPa, the relief valve is automatically triggered to unload. The safety valve is used to realize the overload protection of the system.

[0038] An incremental position encoder is installed on the drive motor shaft end of the electric roller 4. The position encoder is electrically connected to the signal acquisition module of the electronic control system to detect the axial displacement of the H-beam in real time, realize the axial coordinate locking of the deformation area and the precise alignment of the correction mechanism, and the displacement detection accuracy can reach ±0.5mm.

[0039] Example 2 This embodiment provides a method for correcting welded deformation in steel structures, implemented using the steel structure welded deformation correction device described in Embodiment 1, including the following steps: S1 Loading and centering: The H-beam to be corrected is placed on the electric roller 4 using a crane, so that the length direction of the H-beam is perpendicular to the rotation axis of the electric roller 4; the operator inputs the specifications of the H-beam through an industrial touch screen, and the electronic control system automatically generates control commands based on the input parameters: firstly, the first lifting platform 5 is controlled to drive the web guide structure 8 to rise and fall, and the first distance sensor 9 is used to measure the distance. The distance between the web guide structure 8 and the bottom of the H-beam web is fed back in real time, and the web guide structure 8 is raised and lowered to a set height of 10mm from the bottom of the web. Then, the servo motor of the web guide structure 8 is started, driving the symmetrical lead screw 82 to rotate, which drives the brackets 85 on both sides and the guide wheel 87 to move towards each other. The distance between the guide wheel 87 and the inner side of the flange is fed back in real time through the second distance sensor 10, and the guide wheels 87 on both sides are controlled to synchronously fit against the inner surface of the flanges on both sides of the H-beam, so as to complete the precise centering and positioning of the H-beam, while ensuring that the H-beam can move freely along the axial direction.

[0040] S2 Deformation Detection and Data Processing: The electronic control system starts the drive motor of the electric roller 4 and adjusts the speed of the electric roller 4 through the frequency converter, driving the H-beam to move at a constant speed of 5m / min along the length direction. The laser displacement detection light curtain 12 on the two load-bearing columns 1 continuously scans the entire width of the H-beam's two flanges, and collects the distance data between each detection point on the flange surface and the light curtain in real time. At the same time, the position encoder feeds back the axial displacement of the H-beam in real time, and the distance data is matched with the axial coordinates one by one. After the electronic control system performs Kalman filtering on the collected raw data, it fits and generates the surface contour curve of the flange. The contour curve is compared with the standard straight contour, and the maximum bending deformation of the flange is calculated to be 3.2mm. The deformation location is located in the 4m-8m range in the middle of the H-beam, and the deformation type is outward bending of the flange. At the same time, the axial coordinate range of the deformation area is locked.

[0041] S3 Alignment of the Correction Mechanism: The electronic control system automatically generates alignment parameters for the correction mechanism based on the specifications and deformation detection data of the H-beam. It controls the second lifting platform 6 to raise and lower the first inner correction mechanism 13, using the third distance sensor 15 to provide real-time feedback on the distance between the first inner correction mechanism 13 and the bottom of the web, positioning the first inner correction mechanism 13 at the corresponding height inside the lower flange of the H-beam. Simultaneously, it controls the third lifting platform 7 to raise and lower the second inner correction mechanism 14, using the fourth distance sensor 16 to provide real-time feedback on the distance between the second inner correction mechanism 14 and the top of the web, positioning the second inner correction mechanism 14 at the corresponding height inside the upper flange of the H-beam. Simultaneously, it controls the first hydraulic rod 172 of the lifting adjustment mechanism 17 to drive the first outer correction mechanism 18 to raise and lower, ensuring the first outer correction mechanism 18 is at the same height as the first inner correction mechanism 13. Finally, it controls the second hydraulic rod 173 to drive the second outer correction mechanism 19 to raise and lower, ensuring the second outer correction mechanism 19 is at the same height as the second inner correction mechanism 14, thus completing the precise alignment of the inner and outer correction mechanisms.

[0042] S4 Continuous Reciprocating Correction: The electronic control system automatically generates correction force parameters based on the outward bending deformation type of the wing plate and the deformation amount of 3.2mm, setting the system pressure to 8MPa; it controls the extension of the fourth hydraulic rod 135 of the first inner correction mechanism 13 and the second inner correction mechanism 14, driving the inner correction wheels 134 on both sides to extend synchronously and press against the inner surface of the H-beam wing plate; it controls the extension of the third hydraulic rod 185 of the first outer correction mechanism 18 and the second outer correction mechanism 19, driving the outer correction wheel 184 to extend and press against the outer surface of the H-beam wing plate; using the outer correction wheel 18... The staggered arrangement of roller 4 and two inner straightening rollers 134 forms a three-point bending straightening force, which applies a reverse plastic deformation force to the outward bending deformation of the flange. Subsequently, the electric control system controls the electric roller 4 to drive the H-beam to move back and forth along the length direction at a speed of 3m / min, so that the inner and outer straightening rollers continuously roll and straighten the deformation area of ​​the flange. The number of reciprocations is set to 3. During the straightening process, the magnitude of the straightening force is fed back in real time through the pressure sensor, and the extension of the straightening roller is fed back in real time through the displacement sensor, so as to realize the closed-loop dynamic adjustment of the straightening parameters and ensure that the straightening force is stable within the set range.

[0043] S5 Correction Verification and Unloading: After three correction cycles, the electrical control system controls the electric roller 4 to drive the H-beam to move at a constant speed of 5 m / min along its length. The laser displacement detection light curtain 12 scans the entire surface of the H-beam flange again, generating the corrected flange surface profile curve. The residual deformation of the flange is calculated to be 0.3 mm, which is within the preset allowable tolerance of ±0.5 mm, thus the correction is deemed qualified. The electrical control system controls all hydraulic actuators to reset and controls the guide wheel 87 to open. The operator then uses a crane to unload the corrected H-beam.

[0044] If the residual deformation obtained in this test still exceeds the tolerance range, the electronic control system will automatically adjust the correction parameters, increase the system pressure and the extension of the correction wheel, and repeat the correction and testing process of steps S4-S5 until the test results meet the design tolerance requirements.

[0045] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A steel structure welding deformation correction device, comprising a frame assembly, the frame assembly comprising two parallel load-bearing columns (1), the tops of the two load-bearing columns (1) being fixedly connected to a crossbeam (2), characterized in that: Two support boxes (3) are provided between the two load-bearing columns (1). The two support boxes (3) are arranged close to the load-bearing columns (1) on the corresponding side. An electric roller (4) is rotatably connected to the top of the support box (3). A first lifting platform (5) and a second lifting platform (6) are provided between the two support boxes (3). There are two first lifting platforms (5). The second lifting platform (6) is located between the two first lifting platforms (5) and corresponds to the middle position of the crossbeam (2). A third lifting platform (7) is vertically fixedly connected to the top of the crossbeam (2) at the position corresponding to the second lifting platform (6). The top of the first lifting platform (5) is provided with a web plate guide structure (8), the top of the web plate guide structure (8) is provided with a first distance sensor (9), and the two sides of the web plate guide structure (8) are provided with second distance sensors (10). The inner sides of the two load-bearing columns (1) are provided with lifting adjustment mechanisms (17), and laser displacement detection light curtains (12) are vertically fixed on both sides of the lifting adjustment mechanisms (17) by brackets. The top of the second lifting platform (6) is fixedly provided with a first internal correction mechanism (13), and the bottom of the third lifting platform (7) is fixedly provided with a second internal correction mechanism (14). The top of the first internal correction mechanism (13) is provided with a third distance sensor (15), and the bottom of the second internal correction mechanism (14) is provided with a fourth distance sensor (16). The lifting adjustment mechanism (17) is provided with a first external correction mechanism (18) corresponding to the first internal correction mechanism (13) and a second external correction mechanism (19) corresponding to the second internal correction mechanism (14) on one side. The lifting adjustment mechanism (17) adjusts the first external correction mechanism (18) and the first internal correction mechanism (13) to be at the same height, and the second internal correction mechanism (14) and the second external correction mechanism (19) to be at the same height, based on the measurement results of the third distance sensor (15) and the fourth distance sensor (16). The axis of the external correction wheel (184) is located at the corresponding position of the center of the two adjacent internal correction wheels (134).

2. It also includes an electrical control system and a hydraulic control system. The electrical control system is electrically connected to all sensors, electric rollers (4), and motors (83). The hydraulic control system is connected to the hydraulic actuators of the first lifting platform (5), the second lifting platform (6), the third lifting platform (7), the lifting adjustment mechanism (17), the first external correction mechanism (18), the first internal correction mechanism (13), the second internal correction mechanism (14), and the second external correction mechanism (19).

3. The steel structure welding deformation correction device according to claim 1, characterized in that, The web guide structure (8) includes a housing (81), a symmetrical lead screw (82), and a motor (83). The symmetrical lead screw (82) is rotatably connected inside the housing (81), and the motor (83) is fixed inside the housing (81). A synchronous pulley (84) is fixed in the middle of the symmetrical lead screw (82). The motor (83) is connected to the synchronous pulley (84) via a belt. A bracket (85) is symmetrically threaded on the surface of the symmetrical lead screw (82). One end of the bracket (85) extends to the outside of the housing (81) and is fixedly connected to a guide wheel frame (86). A guide wheel (87) is rotatably connected to the surface of the guide wheel frame (86).

4. The steel structure welding deformation correction device according to claim 1, characterized in that, The lifting adjustment mechanism (17) includes a fixed housing (171), a first hydraulic rod (172) is vertically fixedly connected to the bottom of the inner wall of the fixed housing (171), a second hydraulic rod (173) is vertically fixedly connected to the top of the inner wall of the fixed housing (171), and a guide rail (174) is provided on the inner wall of the fixed housing (171); the first external correction mechanism (18) and the second external correction mechanism (19) are both slidably connected to the guide rail (174), the working end of the first hydraulic rod (172) is fixedly connected to the first external correction mechanism (18), and the working end of the second hydraulic rod (173) is fixedly connected to the second external correction mechanism (19).

5. A steel structure welding deformation correction device according to claim 1, characterized in that, The first external correction mechanism (18) includes a lifting housing (181), a telescopic housing (182) is horizontally slidably connected to one side of the lifting housing (181), an external correction wheel frame (183) is fixedly connected to one end of the telescopic housing (182), an external correction wheel (184) is rotatably connected to one side of the external correction wheel frame (183), and a third hydraulic rod (185) is horizontally arranged between the lifting housing (181) and the telescopic housing (182); the second external correction mechanism (19) has the same structure as the first external correction mechanism (18).

6. The steel structure welding deformation correction device according to claim 1, characterized in that, The first internal correction mechanism (13) includes a fixed cylinder (131), with telescopic cylinders (132) symmetrically slidably connected to both ends of the fixed cylinder (131). An internal correction wheel frame (133) is fixedly connected to one end of the telescopic cylinder (132), and an internal correction wheel (134) is rotatably connected to one side of the internal correction wheel frame (133). A fourth hydraulic rod (135) is horizontally arranged between the fixed cylinder (131) and the telescopic cylinders (132) on both sides. The second internal correction mechanism (14) has the same structure as the first internal correction mechanism (13).

7. A steel structure welding deformation correction device according to claim 1, characterized in that, The electrical control system includes a core control unit, a signal acquisition module, a motor drive module, a human-machine interaction module, and a safety protection module. The core control unit adopts an industrial-grade programmable logic controller. The signal acquisition module is electrically connected to all detection elements. The motor drive module is electrically connected to the drive motor of the electric roller (4) and the motor (83) of the web guide structure, respectively. The human-machine interaction module adopts an industrial touch screen that is communicatively connected to the core control unit. The safety protection module includes an emergency stop button, an audible and visual alarm, and a limit sensor.

8. A method for correcting welding deformation in steel structures, characterized in that, The steel structure welding deformation correction device according to any one of claims 1-6 is used to implement the correction, which includes the following steps: S1 Loading and Centering Positioning: The H-beam to be straightened is placed on the electric roller (4). The electrical control system controls the first lifting platform (5) to lift the web guide structure (8) to the set height according to the specifications of the H-beam. The positioning is fed back by the first distance sensor (9). The centering position of the H-beam is completed by using the web guide structure (8). S2 Deformation Detection and Data Processing: Start the electric roller (4) to drive the H-beam to move at a constant speed along the length direction. The laser displacement detection light curtain (12) on both sides continuously scans the H-beam flange across the entire width and collects the flange surface distance data. The electrical control system performs fitting calculations on the collected data to obtain the bending deformation, deformation position, deformation curvature and deformation direction of the flange. At the same time, the axial coordinates of the deformation area are locked by feedback through the position encoder. S3 alignment mechanism: The electronic control system controls the second lifting platform (6) and the third lifting platform (7) to move the first inner alignment mechanism (13) and the second inner alignment mechanism (14) to the corresponding height of the wing plate according to the specifications of the H-beam and the deformation detection data. The positioning is fed back by the third distance sensor (15) and the fourth distance sensor (16). At the same time, the lifting adjustment mechanism (17) is controlled to drive the first outer alignment mechanism (18) to align with the first inner alignment mechanism (13) and the second outer alignment mechanism (19) to align with the second inner alignment mechanism (14). S4 Continuous reciprocating correction: The electronic control system controls the extension of the fourth hydraulic rod (135) of the inner correction mechanism, so that the inner correction wheel (134) presses against the inner surface of the wing plate; controls the extension of the third hydraulic rod (185) of the outer correction mechanism, so that the outer correction wheel (184) presses against the outer surface of the wing plate, and forms a three-point bending correction force through the staggered arrangement of the inner and outer correction wheels; controls the electric roller (4) to drive the H-beam to move reciprocally along the length direction to continuously correct the deformation area. During the correction process, the pressure sensor provides real-time feedback of the correction force to achieve closed-loop regulation. S5 Correction Verification and Material Cutting: After a single correction is completed, the laser displacement detection light curtain (12) scans the H-shaped steel wing plate again to detect the full width. If the deformation of the wing plate is within the preset allowable tolerance range, the correction is completed, all mechanisms are reset, and material cutting is performed. If the deformation is still out of tolerance, repeat steps S4-S5 until the test results meet the tolerance requirements.

9. The method for correcting welding deformation in steel structures according to claim 7, characterized in that, In step S4, the electronic control system dynamically adjusts the output pressure of the hydraulic system and the extension of the correction wheel according to the deformation amount and type of the wing plate. For wing plates that bend outward, the clamping force of the outer correction wheel is increased; for wing plates that bend inward, the clamping force of the inner correction wheel is increased.

10. The method for correcting welding deformation in steel structures according to claim 7, characterized in that, In step S2, the electronic control system filters the collected distance data, fits and generates the surface profile curve of the wing plate, compares the profile curve with the standard straight line, calculates the bending deformation and curvature of the wing plate, and determines whether the deformation direction is inward or outward bending.

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