An assembled steel structure house light steel component automatic production line

Abstract

This invention relates to the field of automation technology for lightweight steel components, and discloses an automated production line for lightweight steel components in prefabricated steel structure residential buildings. The production line includes a central control system, an automatic conveying system, and raw material processing units, laser cutting units, robotic welding units, and shot blasting units arranged sequentially along the material conveying direction. By constructing an integrated production line under the central control system, encompassing raw material processing, laser cutting, robotic welding, and shot blasting, this invention achieves fully automated and collaborative control of lightweight steel components from raw materials to finished products. Compared to existing technologies that focus only on partial improvements to single processes or logistics optimization, this solution enables seamless connection and intelligent scheduling of all processes, effectively breaking down information barriers and connection bottlenecks between processes, and improving material flow efficiency and overall production cycle time.

Description

Technical Field

[0001] This invention relates to the field of automated production technology for lightweight steel components, specifically to an automated production line for lightweight steel components of prefabricated steel structure residential buildings. Background Technology

[0002] Steel structure buildings, due to their prefabricated and environmentally friendly characteristics, have become an important development direction for the construction industry. With the rapid development of prefabricated steel structure housing, the market demand for lightweight steel components such as H-beams and rectangular steel pipes is increasing, placing higher demands on production efficiency and cost control. Existing technologies already include several automation solutions for steel component production. For example, one solution uses an automatic welding module in conjunction with a data acquisition and analysis module to achieve automated quality control of the H-beam welding process; another patented solution designs a production line with a closed-loop track, improving material transfer efficiency through the movement of transport trolleys between the processing track and the rotary track.

[0003] However, existing technical solutions still have certain limitations. The aforementioned solutions focus on the automation optimization of individual welding processes or the material flow of the production line, failing to take a holistic approach and systematically integrate and coordinate all key processes, including raw material handling, laser cutting, robotic welding, quality inspection, and surface treatment. This results in poor coordination between different stages of the production line, making it difficult to form an efficient and coherent automated production flow. Overall production efficiency, product quality stability, and flexible production capabilities still have significant room for improvement, and cannot fully meet the current demand for large-scale, high-quality, and low-cost manufacturing of lightweight steel components in prefabricated steel structure housing. Summary of the Invention

[0004] In view of this, the present invention provides an automated production line for lightweight steel components of prefabricated steel structure residential buildings, in order to solve the problems of existing steel component production lines that only partially optimize a single process or logistics link, lack systematic integration and coordination of the entire process, resulting in poor link connection, insufficient production efficiency and quality stability, weak flexible production capacity, and difficulty in meeting the large-scale, high-quality, and low-cost manufacturing needs of lightweight steel components for prefabricated steel structure residential buildings.

[0005] This invention provides an automated production line for lightweight steel components of prefabricated steel structure residential buildings, including a central control system, an automatic conveying system, and raw material processing units, laser cutting units, robotic welding units, and shot blasting units arranged sequentially along the material conveying direction. The raw material processing unit is used to stack raw materials and connect the cut residues. The laser cutting unit is used to cut, drill holes, and bevele the raw materials. The robotic welding unit is used to automatically weld the raw materials to form prefabricated parts. The shot blasting unit is used to perform quality inspection and surface shot blasting rust removal on the prefabricated parts. The automatic conveying system is set between the units for automatically transferring materials between the units. The central control system is used for production scheduling. It stores a database of processing requirements and sends processing information to the raw material processing unit, the laser cutting unit, the robotic welding unit, and the shot blasting inspection unit.

[0006] Beneficial effects: This invention provides an automated production line for lightweight steel components in prefabricated steel structure residential buildings. By constructing an integrated production line encompassing raw material processing, laser cutting, robotic welding, and shot blasting inspection units under a central control system, it achieves fully automated and collaborative control of lightweight steel components from raw materials to finished products. Compared to existing technologies that focus only on partial improvements to single processes or logistics optimization, this solution enables seamless connection and intelligent scheduling across all processes, effectively breaking down information barriers and bottlenecks between processes, and improving material flow efficiency and overall production rhythm. Simultaneously, relying on the refined scheduling and process data support of the central control system, this invention improves the consistency of product welding quality and dimensional accuracy, and strengthens the production line's flexible production capabilities in response to diverse component orders.

[0007] Optionally, the automated conveying system includes: RGV mother-daughter vehicle, which moves along a preset track and is used to transport raw materials or prefabricated parts between processing units; AGV (Automated Guided Vehicle); the AGV moves along a preset path and is used to transport prefabricated parts between the raw material processing unit and the robotic welding unit.

[0008] Optionally, the raw material processing unit includes: A raw material storage yard, used for storing raw materials to be processed; A collaborative welding robot is positioned next to the raw material stockpile and is used to butt weld the cut scraps.

[0009] Optionally, the laser cutting unit includes: A raw material storage unit is located at the entrance of the laser cutting unit and is used to temporarily store raw materials. A laser profile cutting machine is installed on the discharge side of the raw material silo and is used to cut, drill holes and bevele the raw materials. A semi-finished product storage unit is located on the discharge side of the laser profile cutting machine and is used to temporarily store the cut semi-finished products.

[0010] Optionally, the laser cutting unit further includes: A steel transfer machine is installed on one side of the laser profile cutting machine to receive raw materials that do not require secondary processing after cutting. An output roller conveyor is connected to the steel transfer machine and is used to output and store raw materials that have been cut and do not require secondary processing from the steel transfer machine.

[0011] Optionally, the robotic welding unit includes a stiffener assembly area, a steel bracket welding area, an automated welding workstation, and a collaborative welding robot; The stiffener assembly area and the steel bracket welding area are respectively located at different workstations of the robot welding unit, and are used for the assembly of stiffeners and steel brackets respectively. The automatic welding workstation is located on the discharge side of the stiffener assembly area and is used to automatically weld the raw materials of the assembled stiffener. The collaborative welding robot is positioned in the welding area of ​​the steel bracket component and is used to weld the raw materials of the assembled steel bracket.

[0012] Optionally, the robotic welding unit further includes a positioner, which is located at the automatic welding workstation and the collaborative welding robot, and is used to clamp and rotate the raw material to a preset welding posture.

[0013] Optionally, the shot blasting detection unit includes: A three-dimensional laser scanner is installed at the inspection station and is used for non-contact inspection of the dimensions and geometric tolerances of prefabricated parts. A shot blasting chamber is located on the discharge side of the three-dimensional laser scanner and is used to perform shot blasting and rust removal treatment on the surface of precast parts that have passed inspection.

[0014] Optionally, the central control system includes a data acquisition module, a data modeling module, a data fusion module, a data calculation module, and a data subscription and message notification module; The data acquisition module is used to collect the operating status data of each unit and device; The data modeling module is used to construct a physical model of the device based on the collected data; The data fusion module is used to fuse and analyze the collected operational status data and business data; The data calculation module is used to generate control commands based on the analysis results; The data subscription and message notification module is used to send control commands to each unit and device, and to provide alarm notifications for abnormal states.

[0015] Optionally, the raw materials include rectangular steel pipes, H-beams, and reinforcing steel plates. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a flowchart illustrating an automated production line for lightweight steel components of prefabricated steel structure residential buildings, according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the components of the raw material processing unit according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the components of the laser cutting unit according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the components of the robot welding unit according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the components of the shot blasting detection unit according to an embodiment of the present invention; Explanation of reference numerals in the attached figures: 1. Automated conveying system; 11. RGV (Automated Guided Vehicle); 12. AGV (Automated Guided Vehicle); 13. Overhead crane; 2. Raw material handling unit; 21. Raw material storage yard; 22. Collaborative welding robot; 3. Laser cutting unit; 31. Raw material vertical storage unit; 32. Laser profile cutting machine; 33. Semi-finished product vertical storage unit; 34. Steel transfer machine; 4. Robotic welding unit; 41. Rib plate assembly area; 42. Steel bracket component welding area; 43. Automated welding workstation; 44. Tilting machine; 5. Shot blasting unit; 51. 3D laser scanner; 52. Sandblasting room; Detailed Implementation To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0018] The following is combined Figures 1 to 5 The following describes embodiments of the present invention.

[0019] According to an embodiment of the present invention, an automated production line for lightweight steel components of prefabricated steel structure residential buildings is provided, including a central control system, an automatic conveying system 1, and a raw material processing unit 2, a laser cutting unit 3, a robotic welding unit 4, and a shot blasting unit 5 arranged sequentially along the material conveying direction. The raw material processing unit 2 is used to stack raw materials and dock the cut residues. The laser cutting unit 3 is used to cut, open, and bevele the raw materials. The robotic welding unit 4 is used to automatically weld the raw materials to form prefabricated parts. The shot blasting unit 5 is used to perform quality inspection and surface shot blasting rust removal on the prefabricated parts. The automatic conveying system 1 is set between each unit for automatically transferring materials between each unit. The central control system is used for production scheduling. It stores a database of processing requirements and sends processing information to the raw material processing unit 2, laser cutting unit 3, robotic welding unit 4, and shot blasting inspection unit 5.

[0020] The automated production line for lightweight steel components of prefabricated steel structure residential buildings provided in this embodiment achieves fully automated and collaborative control of lightweight steel components from raw materials to finished products by constructing an integrated production line with five units—raw material processing, laser cutting, robotic welding, and shot blasting inspection—under the leadership of a central control system. Compared to existing technologies that only focus on partial improvements in single processes or logistics optimization, this solution enables seamless connection and intelligent scheduling of all processes, effectively breaking down information barriers and connection bottlenecks between processes, and improving material flow efficiency and overall production rhythm. Simultaneously, relying on the refined scheduling and process data support of the central control system, this invention improves the consistency of product welding quality and dimensional accuracy, and strengthens the production line's flexible production capability in the face of diverse component orders.

[0021] Furthermore, the automated conveying system 1 includes: RGV mother-daughter carriage 11 moves along a preset track and is used to transport raw materials or prefabricated parts between processing units; AGV (Automated Guided Vehicle) 12: The AGV moves along a preset path and is used to transport prefabricated parts between the raw material processing unit 2, the laser cutting unit 3, and the robotic welding unit 4.

[0022] It should be noted that the automated conveying system 1 adopts a combined layered conveying mode of RGV mother-daughter carts 11 and AGV automated guided vehicles 12. Both types of equipment are uniformly scheduled by the central control system. The RGV mother-daughter carts 11 run along fixed tracks that run through each main processing unit. Relying on the high-precision positioning capability of the tracks, they can carry large-sized and heavy raw materials and prefabricated parts such as H-beams and rectangular steel pipes. They can achieve long-distance and large-volume precise transfer between main process units arranged in a straight line, such as the raw material processing unit 2, laser cutting unit 3, and shot blasting inspection unit 5. They can accurately connect to the inbound and outbound ports of each unit's vertical warehouse. The AGV automated guided vehicles 12 run on flexible preset navigation paths and are specifically responsible for the flexible transfer of small prefabricated parts, scrap splicing blanks, and other scattered materials between the raw material processing unit 2 and the robotic welding unit 4. The transport path can be dynamically adjusted according to the real-time operation status of the production line.

[0023] In essence, the combined conveying solution using RGVs and AGVs addresses the transfer needs of materials of different specifications, effectively solving the problem of insufficient adaptability of single conveying equipment. The RGV mother-daughter vehicle 11, relying on the high load-bearing capacity, high stability, and high-precision positioning capabilities of rail transport, can efficiently complete long-distance transfers of large-sized main materials, ensuring the stability and consistency of material supply between various processes in the main production line, and avoiding shaking and positioning deviations during the transport of heavy-load materials. The AGV automated guided vehicle 12, with its flexible path, adapts to the flexible transfer needs of scattered small materials, completing cross-unit material scheduling without occupying the main conveying track, effectively alleviating the transport pressure on the main track and avoiding logistics congestion. The collaborative operation of these two types of equipment improves the efficiency and flexibility of the production line's logistics flow, completely solving the problem of poor material transfer connections between units in traditional production lines, and ensuring continuous operation of the entire production line.

[0024] Furthermore, the automated conveying system 1 also includes a crane 13, which is positioned above each unit and is used to lift heavy raw materials or prefabricated components within and between units.

[0025] Specifically, the overhead crane 13, as an aerial logistics node of the automated conveying system 1, has its track laid on top of the raw material processing unit 2, laser cutting unit 3, robotic welding unit 4, and inspection shot blasting unit 5. It can move longitudinally and laterally along the factory building to realize the vertical lifting and horizontal cross-area transfer of materials. In the raw material processing unit 2, the overhead crane 13 is responsible for lifting and unloading rectangular steel pipes, H-beams, and parts plates transported by flatbed trucks from the transport vehicles to the raw material storage yard 21, and lifting the leftover materials generated after laser cutting to the leftover material docking station. In the inspection shot blasting unit 5, the overhead crane 13 lifts the welded finished components to the grinding and inspection area, and lifts the sandblasted components to the finished product buffer area and the painting workshop. The three-dimensional logistics network formed by the overhead crane 13, the RGV mother-daughter vehicle 11, and the AGV automated guided vehicle 12 fills the gap of RGV and AGV in vertical material transfer and large-scale cross-area lifting, ensuring the safe and efficient flow of heavy materials between various processes.

[0026] Furthermore, the raw material processing unit 2 includes: Raw material storage yard 21 is used to store raw materials to be processed; Collaborative welding robot 22 is located next to the raw material storage yard 21 and is used to butt weld the cut scraps.

[0027] Specifically, such as Figure 1 As shown, the raw material processing unit 2 includes a raw material storage yard 21 and a collaborative welding robot 22. The raw material storage yard 21 is used to store rectangular steel pipes, H-shaped steel components, and parts such as stiffening plates and steel brackets to be processed. After the flatbed truck transports the above-mentioned profiles and parts into the raw material processing unit 2, the overhead crane 13 lifts the profiles to the raw material storage yard 21 for storage and transfers the stiffening plates and steel brackets to a special transfer frame. The collaborative welding robot 22 is set up next to the raw material storage yard 21 and is used to automatically butt weld the leftover materials of rectangular steel pipes and H-shaped steel components generated after laser cutting, so as to realize the recycling and reuse of the leftover materials.

[0028] In an easy-to-understand way, by setting up the raw material storage yard 21 and the collaborative welding robot 22, the centralized classification and stacking of profiles and parts and the automated docking of scrap materials are realized. The collaborative welding robot 22 can automatically complete the docking and welding of the scrap materials after cutting, which effectively improves the utilization rate of scrap materials, reduces material waste, and lowers production costs. At the same time, this unit is coordinated with subsequent laser cutting, robotic welding and other processes to ensure the continuity of material supply and the automation level of scrap material recycling in the production line.

[0029] Furthermore, the laser cutting unit 3 includes: Raw material storage 31 is located at the entrance of the laser cutting unit 3 and is used to temporarily store raw materials. Laser profile cutting machine 32 is installed on the discharge side of raw material storage 31 and is used to cut, open and bevel raw materials. The semi-finished product vertical storage 33 is located on the discharge side of the laser profile cutting machine 32 and is used to temporarily store the cut semi-finished products.

[0030] It should be noted that the laser cutting unit 3 is composed of a raw material storage 31, a laser profile cutting machine 32, and a semi-finished product storage 33 arranged sequentially. For example... Figure 2 As shown, the raw material storage unit 31 is located at the entrance of the laser cutting unit 3, where H-beams and rectangular steel pipes can be temporarily stored in batches for processing. It works with the RGV mother-daughter trolley 11 to achieve automated warehousing and supply of raw materials. The laser profile cutting machine 32 is located on the discharge side of the raw material storage unit 31. According to the instructions of the central control system, it performs high-precision cutting, hole drilling, locking, beveling, and marking operations on the profiles. The semi-finished product storage unit 33 is located on the discharge side of the laser profile cutting machine 32. It is used to centrally buffer the semi-finished components that have been cut and processed, supporting on-demand retrieval and flexible production scheduling. At the same time, the cutting waste is returned to the raw material processing unit 2 for docking and reuse through the waste material roller conveyor.

[0031] In a straightforward manner, the integrated layout of the raw material storage unit 31, the laser profile cutting machine 32, and the semi-finished product storage unit 33 enables automated and continuous operation of the laser cutting process. The raw material storage unit 31 improves the storage density and supply stability of raw materials, avoiding downtime due to material shortages; the laser profile cutting machine 32 ensures the processing accuracy and consistency of component cutting, hole drilling, and beveling, improving cutting quality and efficiency; the semi-finished product storage unit 33 enables the orderly buffering and flexible scheduling of cut semi-finished products, effectively connecting upstream and downstream processes, balancing production line cycle time, and, in conjunction with the surplus material return and reuse mechanism, improving material utilization and the overall economy of the production line.

[0032] Furthermore, the laser cutting unit 3 also includes: Steel transfer machine 34 is set on one side of laser profile cutting machine 32 and is used to receive raw materials that do not require secondary processing after cutting. The output roller conveyor is connected to the steel transfer machine 34 and is used to output and store the raw materials that have been cut and do not require secondary processing in the steel transfer machine 34.

[0033] Specifically, such as Figure 2As shown, the laser cutting unit 3 adds a steel transfer machine 34 and an output roller conveyor to one side of the laser profile cutting machine 32. The steel transfer machine 34 directly receives the finished components that have been processed by the laser profile cutting machine 32 and do not need to enter the subsequent robotic welding unit 4 for secondary welding, and smoothly transfers them to the docking output roller conveyor. The output roller conveyor receives the components conveyed by the steel transfer machine 34 and continuously conveys them backward according to the production line rhythm, directly sending them to the grinding and inspection area for subsequent testing and inspection, realizing the rapid diversion and direct conveying of components that do not require secondary processing.

[0034] In a straightforward manner, by adding a steel transfer machine 34 and an output roller conveyor to form an independent diversion and conveying channel, components that do not require secondary welding can be quickly sorted and directly conveyed, avoiding such components from entering the welding unit and causing ineffective flow and workstation occupation. This effectively simplifies the logistics path and reduces process detours. At the same time, it enables the rapid off-line and orderly conveying of finished products, improves the output efficiency of the laser cutting unit 3, further optimizes the production line cycle balance, and enhances the flexibility and adaptability of the production line and the overall flow efficiency.

[0035] Furthermore, the robotic welding unit 4 includes a stiffener assembly area 41, a steel bracket welding area 42, an automatic welding workstation 43, and a collaborative welding robot 22. The stiffener assembly area 41 and the steel bracket welding area 42 are respectively set at different workstations of the robot welding unit 4, and are used for the assembly of stiffeners and steel brackets respectively. An automatic welding workstation 43 is located on the discharge side of the stiffener assembly area 41 and is used to automatically weld the raw materials of the assembled stiffeners. The collaborative welding robot 22 is set in the welding area 42 of the steel bracket component and is used to weld the raw materials of the assembled steel bracket.

[0036] Furthermore, the robotic welding unit 4 also includes a flipping machine 44. The flipping machine 44 is arranged between the assembly area and the welding area, and can perform multi-positional displacement and flipping of components to ensure optimal assembly and welding posture.

[0037] Specifically, such as Figure 3 As shown, the robot welding unit 4 is divided into two independent workstations: the stiffener assembly area 41 and the steel bracket assembly area 42, which respectively complete the assembly of stiffeners, steel brackets, H-beams, and rectangular steel pipes. The automatic welding workstation 43 is located on the material discharge side of the stiffener assembly area 41, which receives the assembled components and performs fully automatic full welding on the stiffeners. The collaborative welding robot 22 is arranged around the steel bracket assembly area 42 to perform high-precision automated welding on the steel bracket nodes, forming a work mode of zoned assembly and specialized welding by equipment.

[0038] In an easy-to-understand way, the layout design of partitioned assembly and dedicated welding machines allows the assembly and welding processes of stiffening plates and steel brackets to be carried out in parallel without interference, thereby improving the overall work efficiency of the welding unit. The flipping machine 44, in conjunction with displacement and posture adjustment, effectively reduces assembly errors, controls welding deformation, and improves the dimensional accuracy of components and the quality of welds. The automatic welding workstation 43 and the collaborative welding robot 22 each perform their respective functions, ensuring both high efficiency in batch stiffening plate welding and flexibility and adaptability in steel bracket joint welding, thereby improving the automation level and flexible production capacity of the production line.

[0039] It should be noted that stiffening plates are standardized reinforcing auxiliary components used in conjunction with lightweight steel main components such as H-beams and rectangular steel pipes. They are typically small, regularly cut steel plates, mainly used at the edges of door and window openings, beam-column connection nodes, or areas of concentrated load in the main components. By welding them to the web and flanges of the main components, they effectively enhance the local stiffness and resistance to instability, disperse concentrated stress, and prevent local buckling or deformation of the main components during loading, thus ensuring the structural strength and stability of the lightweight steel components. Because these components have uniform specifications and regular welding paths, they are suitable for automated batch welding operations, making them standardized processing objects for independent workstations in production lines.

[0040] It should be noted that the steel bracket component is a core supporting component in prefabricated steel structure housing, used to achieve dry connection of prefabricated components. Essentially a small cantilever load-bearing component, it is typically assembled from multiple welded steel plates. One end can be firmly welded to the main steel components such as steel columns and main beams, while the other end cantilevers outward to form a supporting platform. In housing assembly construction, this component is mainly used to support the ends of prefabricated floor slabs, secondary beams, or external wall panels, effectively transferring the upper load to the main structure. It also eliminates the need for on-site high-altitude welding operations, enabling rapid dry connection of components and improving on-site assembly efficiency. Due to the complex welding joint shapes and varied weld trajectories of the steel bracket, higher requirements are placed on the flexibility and precision of the welding operations. Therefore, a collaborative welding robot 22 is used in the production line to adapt to its personalized processing needs.

[0041] Furthermore, the robotic welding unit 4 also includes a positioner, which is located at the automatic welding workstation 43 and the collaborative welding robot 22, and is used to clamp and rotate the raw material to a preset welding posture.

[0042] Specifically, the positioner is installed at the workstation of the automatic welding workstation 43 and the collaborative welding robot 22. It integrates a special clamping mechanism to firmly clamp and position various main components such as H-beams and rectangular steel pipes. The equipment can be linked and coordinated with the central control system and the welding robot. According to the welding process requirements of different components, it can automatically drive the components to rotate and pitch in multiple dimensions, and accurately adjust the weld seam to be welded to the preset optimal welding posture. It is suitable for the continuous posture switching of multiple weld seams in the batch welding of stiffening plates, and can also meet the multi-angle position adjustment when welding complex nodes of steel brackets, ensuring the precise control of the component posture during the welding operation.

[0043] In a straightforward manner, by configuring a positioner at the welding station, various weld seams can be uniformly adjusted to a flat welding posture, effectively avoiding challenging welding operations such as overhead and vertical welding, reducing the difficulty of welding operations, and improving weld formation quality and penetration stability, effectively reducing welding defects such as porosity and incomplete penetration. In addition, the positioner-driven active displacement mode of components replaces the complex spatial posture adjustment of the welding robot itself, simplifies the robot's motion trajectory, reduces equipment idle travel and motion redundancy, effectively improves welding efficiency, and reduces the robot's motion load and wear. This ensures the cycle speed of batch stiffener welding, improves the accessibility and precision of welding complex nodes of steel brackets, and further enhances the work quality and flexible adaptability of the welding unit.

[0044] Furthermore, the shot blasting unit 5 includes: A 3D laser scanner 51 is installed at the inspection station and is used for non-contact inspection of the dimensions and geometric tolerances of prefabricated parts. Sandblasting chamber 52 is located on the discharge side of 3D laser scanner 51 and is used to perform shot blasting and rust removal treatment on the surface of qualified precast parts.

[0045] Specifically, such as Figure 4 As shown, the shot blasting unit 5 is arranged with a 3D laser scanner 51 and a sandblasting chamber 52 in sequence along the material conveying direction. The 3D laser scanner 51 is located at the inspection station at the unit entrance. It can perform full-size non-contact scanning of the precast parts output by the robotic welding unit 4. It automatically uploads the collected component point cloud data to the central control system and compares it with the standard design model stored in the system to complete the fully automatic inspection and qualification judgment of component dimensional accuracy, form and position tolerance and weld appearance. The qualified precast parts will be transferred to the downstream sandblasting chamber 52 through the automatic conveying system 1. The shot blasting equipment in the sandblasting chamber 52 will automatically clean the oxide scale, welding slag and rust layer on the surface of the components. The unqualified components will be automatically diverted to the rework station.

[0046] In a straightforward manner, the process layout of first inspecting and then shot blasting, combined with a fully automated non-contact inspection solution using a 3D laser scanner 51, replaces the inefficient traditional manual caliper inspection mode. Non-contact operation prevents scratches or damage to the component surface, improving inspection efficiency and accuracy. It enables full coverage inspection of all component dimensions, avoiding manual omissions. Simultaneously, the inspection data is automatically stored, enabling full quality traceability and effectively ensuring the quality stability of finished components. Furthermore, this layout prevents unqualified components from entering the shot blasting process, reducing unnecessary labor and material waste. The centralized shot blasting treatment in the enclosed sandblasting chamber 52 effectively removes impurities from the component surface and allows for shot recycling and centralized dust treatment, ensuring environmental friendliness. This further enhances the adhesion of coatings in subsequent painting processes, guaranteeing the corrosion resistance and appearance quality of the finished components.

[0047] Furthermore, the central control system includes a data acquisition module, a data modeling module, a data fusion module, a data computing module, and a data subscription and message notification module; The data acquisition module is used to collect operating status data from each unit and device; The data modeling module is used to build a physical model of the device based on the collected data; The data fusion module is used to integrate and analyze the collected operational status data and business data; The data calculation module is used to generate control commands based on the analysis results; The data subscription and message notification module is used to send control commands to each unit and device, and to provide alarm notifications for abnormal states.

[0048] Specifically, the central control system, acting as the brain of the entire production line, forms a complete closed-loop data processing chain through its internal functional modules: the data acquisition module collects real-time, multi-dimensional data on the operating status, processing parameters, and material positions of all units, including raw material processing, laser cutting, robotic welding, shot blasting, and terminal equipment such as RGVs, AGVs, and welding robots, via an industrial internet interface; the data modeling module constructs a digital twin physical model of the equipment and production line based on the collected equipment parameters and operating data, realizing a digital mapping of the actual state of the production line; the data fusion module integrates the collected equipment operating data with business data such as order scheduling, process requirements, and quality standards, completing cross-process and cross-equipment data correlation analysis; the data calculation module automatically generates corresponding control commands for production scheduling, process adjustment, and material transfer based on the fusion analysis results, combined with process algorithms and scheduling logic; and finally, the data subscription and message reminder module accurately synchronizes the control commands to each terminal unit and equipment through a subscription and distribution mechanism, while simultaneously monitoring the production line status in real time and automatically triggering alarms for equipment failures, quality anomalies, and other conditions.

[0049] In simple terms, this modular central control system constructs a closed-loop data management system for the entire production line, completely breaking down information barriers between different processes and equipment in traditional production lines. It achieves fully automated processing from data acquisition, status mapping, fusion analysis to command issuance. Relying on digital twin physical models and multi-source data fusion analysis, the system can achieve real-time perception and accurate prediction of the overall status of the production line. It can automatically complete production scheduling and dynamic dispatching based on order demand and equipment operating status, balance the work rhythm of each process, and maximize the utilization rate of the production line. At the same time, the automatic command issuance and abnormal alarm mechanism reduce the cost of manual intervention, realize rapid response and handling of faults, effectively reduce the risk of unplanned downtime, and ultimately support the collaborative management of the entire production line process, improve the automation level, production efficiency and quality stability of the production line, and fully meet the needs of large-scale flexible production.

[0050] Furthermore, the raw materials include rectangular steel pipes, H-beam steel components, and reinforcing steel plates.

[0051] It should be noted that rectangular steel pipes are one of the core raw materials processed on this production line. These are standardized cold-formed or hot-rolled lightweight rectangular steel pipes, characterized by their regular cross-section and uniform mechanical properties. They are the core substrate for steel columns and load-bearing components of partition walls in prefabricated steel structure residential buildings. In the processing flow of this production line, these raw materials will undergo laser cutting, node drilling, and beveling in sequence. Subsequently, the robotic welding unit 4 will complete the welding of auxiliary components such as stiffening plates and steel brackets, ultimately processing them into prefabricated column components that can be directly transported to the site for assembly. Their regular cross-sectional characteristics perfectly adapt to the automated conveying, cutting, and welding operations of the production line, ensuring processing accuracy and efficiency.

[0052] It should be noted that H-beams are another core raw material in this production line. They are mostly lightweight high-frequency welded H-beams or hot-rolled H-beams, which have the advantages of strong bending load-bearing capacity and light weight. They are the core base material for load-bearing components such as main beams and secondary beams in prefabricated steel structure houses. In the production line processing flow, these raw materials will first be cut to a fixed length, with node opening and beveling completed by the laser cutting unit 3. Then, in the robotic welding unit 4, processes such as stiffening of ribs and welding of steel brackets will be completed, finally forming prefabricated beam components. Their standardized cross-sectional shape can adapt to the processing requirements of the entire automated production line, ensuring consistency and operational efficiency in batch production.

[0053] It should be noted that reinforcing steel plates are auxiliary raw materials for this production line. They are small, neatly cut steel plates, mainly used as the base material for processing auxiliary functional components such as reinforcing ribs and steel brackets. In the production line operation process, this type of raw material can be pre-cut and then precisely assembled and welded with main components such as rectangular steel pipes and H-beams in robotic welding unit 4. This enhances the local rigidity of the main components and provides assembly support nodes for prefabricated components. Its standardized dimensions perfectly adapt to automated assembly and welding operations, effectively ensuring the processing accuracy and assembly efficiency of auxiliary components.

[0054] Here, the processes in the embodiments are described: The raw material pretreatment and waste recycling process is the front-end preparation process of the production line. It is responsible for the standardized storage of raw materials and the recycling and regeneration of waste materials. Various raw materials such as rectangular steel pipes, H-beams, and steel plates are classified and stored in the raw material storage yard 21 and the automated warehouse to achieve intensive storage and precise outbound management. For the scattered waste materials that meet the reuse standards generated by the laser cutting process, the production line uses collaborative welding robots 22 arranged adjacent to the storage yard to automatically position, connect, and weld the waste materials, splicing the scattered waste materials into qualified blanks that can be reprocessed, realizing the recycling and reuse of raw materials, effectively reducing material loss and production costs, while ensuring the continuity of raw material supply to the production line.

[0055] This embodiment establishes a complete process specification for the recycling and reuse of leftover materials from finished rectangular steel pipes and H-beams. The process strictly adheres to four core principles: First, the principle of equal strength, requiring butt welds to be full penetration welds with a quality grade of not less than level two, with butt welds subjected to tension or dynamic loads requiring level one; second, the principle of staggered alignment, requiring the splice distance between the flanges and webs of H-beams to be not less than 200mm; third, the principle of minimum length, requiring the splice length to be not less than 600mm, and for hot-rolled steel, simultaneously meeting the requirements of not less than twice the cross-sectional height and not less than 600mm; and fourth, the principle of pre-assembly followed by post-assembly, requiring the butt welding of leftover materials to be completed before component assembly, and subsequent welding operations can only proceed after post-weld correction is deemed satisfactory.This process, applicable to both welded and hot-rolled H-beams, involves cutting and beveling. Cutting can be done using flame or plasma cutting methods, ensuring the cross-section is free of cracks, delamination, and slag inclusions. After cutting, the slag is removed and the surface is ground until a metallic luster is exposed. For the beveling, a V-shaped or double V-shaped bevel is used between the flanges and the web, with the bevel angle controlled at 60°±5°, a blunt edge of 0 to 2 mm, and a gap of 2 to 4 mm. If the thickness difference is greater than 4 mm, a 1:2.5 gentle slope transition is required. Simultaneously, a weld hole with a radius of approximately 15 mm is needed in the web to avoid stress concentration. In the middle stage, after processing, assembly and positioning are carried out. A rigid assembly platform is used to ensure the straightness and flatness of the components. The center lines of the flange plates and web plates are aligned, and the misalignment is controlled to be no more than one-tenth of the plate thickness and no more than 2mm. The tack welds use the same type of welding material as the formal welds and are performed by certified welders. The length of the tack weld is not less than 50mm, the spacing is 300 to 500mm, the weld leg height is not less than 4mm, and the weld is free of cracks, porosity, and slag inclusions. At the same time, arc-starting and arc-extinguishing plates of the same material and bevel are installed at both ends of the component. After welding, they are removed and ground flat. The welding process is based on the matching of the base material. Welding materials: E43 series welding materials are used for Q235 material, and E50 series welding materials are used for Q355 material. The welding materials are dried and kept at the required temperature. For thick plates, preheating is carried out according to specifications. For Q355 material plates with a thickness of not less than 32mm, the preheating temperature is controlled at 80-100℃; for plates with a thickness of not less than 50mm, the preheating temperature is controlled at 100-150℃. The welding sequence is to prevent deformation by first welding the web plate, using a multi-layer, multi-pass, symmetrical welding method, followed by welding the flange plates. Deformation is controlled by simultaneous, segmented back-welding operations from both sides. The welding direction is from the middle to both ends to avoid generating restraint stress. The welds must be fully penetrated, free from cracks, incomplete penetration, slag inclusions, and porosity defects. The weld leg and reinforcement height must meet the specifications. Post-weld cleaning of slag and spatter must be completed. Post-weld straightening and inspection should be carried out, using either cold or hot straightening methods. Hot straightening temperature should be controlled between 600 and 800℃ to ensure that the straightness, perpendicularity, and torsion of the components meet the requirements. Visual inspection should show no cracks, weld beads, or pit defects. Non-destructive testing should be performed, with 100% ultrasonic testing for Class I welds and 20% ultrasonic testing for Class II welds. Dimensional deviations must meet the requirements of the "Standard for Acceptance of Construction Quality of Steel Structures" GB50205.For the butt welding of rectangular steel pipe scraps, the first step is to cut and bevele the pipes. The cut ends must be perpendicular, and burrs and slag must be thoroughly cleaned. The beveling should be a single-sided or double-sided V-shape, with an angle controlled at 60°±5°, a blunt edge of 0 to 2mm, and a gap of 2 to 4mm. If the wall thickness difference is greater than 4mm, a 1:2.5 gentle slope transition should be processed. During assembly and positioning, the pipe ends should be aligned, controlling the misalignment to be no more than one-tenth of the wall thickness and no more than 2mm. The straightness of the component should be no more than one-thousandth. Tack welds should be evenly distributed along the circumference, with a weld length of no less than 30mm and a spacing of 100 to 150mm. No defects; welding adopts argon arc welding for the root pass followed by CO2 gas shielded welding for the filler and cover pass. This process can be used for thick-walled components, or manual arc welding can be used. Welding adopts symmetrical segmented welding, and the operation is carried out in the order of four points, eight points, two points, and ten points to control the roundness and deformation of the components. The weld is required to be fully penetrated, continuous, uniform and full. When required, the inner weld should be smooth. After welding, cold straightening is used to ensure the straightness and roundness of the components. Visual inspection and ultrasonic testing are completed. The dimensions meet the requirements of "Cold-formed Steel" GB / T6728 and "Standard for Acceptance of Construction Quality of Steel Structures" GB50205. This process is equipped with general quality control and acceptance standards. Regarding splicing length, the flange splicing length of H-beams should be no less than twice the plate width and no less than 600mm; the web splicing length should be no less than 300mm wide and 600mm long. Only one joint is allowed per section of rectangular steel pipe, with a minimum splicing length of 600mm, and no less than 1000mm for pipe diameters greater than 800mm. Regarding weld quality, full penetration is required, free from cracks, incomplete penetration, slag inclusions, and dense porosity defects. First-class welds must pass 100% ultrasonic testing, and second-class welds must pass 20% ultrasonic testing. Appearance must meet certain requirements. The weld reinforcement should be 0 to 3 mm, with no weld beads or arc craters, and the undercut depth should not exceed 0.5 mm. Dimensional deviations must strictly comply with the "Standard for Acceptance of Construction Quality of Steel Structures" GB50205. The straightness deviation of the components should not exceed one-thousandth of the component length and not exceed 5 mm. The twist of H-beams should not exceed one-two-fiftieth of the section height and not exceed 5 mm. The misalignment should not exceed one-tenth of the plate thickness and not exceed 2 mm. At the same time, a complete set of documents, including material cutting records, assembly records, welding records, preheating and layer temperature records, ultrasonic test reports, correction records, and acceptance records, must be kept.

[0056] The laser precision cutting process is a preliminary forming process for components. After the raw materials are automatically discharged from the raw material warehouse 31, they are sent to the laser profile cutting machine 32. The machine completes the fixed-length cutting, node opening, locking, beveling and marking operations of the profile according to the process instructions issued by the central control system, achieving high-precision preliminary processing. After processing, the semi-finished products can be flexibly diverted according to subsequent needs. Finished components that do not require secondary welding will be directly diverted off the line by the steel transfer machine 34 and the output roller conveyor to avoid ineffective flow. Semi-finished products that need to be welded later are temporarily stored in the semi-finished product warehouse 33 for buffering to balance the cycle time of the preceding and following processes. At the same time, the leftover material generated by cutting will be returned to the raw material processing unit 2 for recycling. The entire process realizes the integrated operation of cutting processing, material diversion and leftover material return.

[0057] Laser cutting and drilling processes for finished rectangular steel pipes and H-beams include two specialized operations: laser cutting and laser drilling. Laser cutting is suitable for various processing needs of finished hot-rolled or welded H-beams and rectangular steel pipes. It can complete fixed-length cutting, end beveling, interlocking, weld hole cutting, corner cutting, as well as opening holes, notches, and irregular cutting of webs and flanges. It can also achieve integrated cutting of steel structure nodes, corbels, and connecting plates. Before cutting, components must be straightened and leveled. Components with excessive bending or twisting should not be processed. The surface of raw materials must be free of thick oxide scale, severe rust, oil stains, and paint to avoid affecting cutting quality. Processing is carried out using a 6kW to 20kW three-dimensional steel-specific laser cutting machine that supports direct CNC program processing. The cutting auxiliary gas is selected according to requirements; oxygen is generally used for carbon steel cutting, while nitrogen is used when oxidation-free and a smooth cross-section is required. Before cutting, the drawings, CNC program, component specifications, material, length, and hole position information must be checked. The cutting process involves component loading, automatic edge finding and alignment, clamping and positioning, followed by program verification and trial cutting of the first piece. After passing the test, formal laser cutting is carried out, sequentially completing cutting, hole opening and notch cutting, beveling, welding hole cutting and end corner cutting. After cutting, slag removal, deburring and grinding are completed, followed by dimensional inspection. After marking, the process moves to the next step. The key points of process control during cutting are clearly defined. Regarding the cutting sequence, for H-beams, the web is cut first, followed by the flanges, to avoid stress concentration leading to deformation. Rectangular steel pipes are cut symmetrically in segments to prevent pipe end deformation and corner collapse. Long components are cut continuously from one end to the other to reduce accumulated thermal deformation. For beveling, V-shaped beveling and single-sided beveling are commonly used. Beveling angles are selected according to the drawings: 45°, 55°, or 60°. Strict control of the consistency between the blunt edge and the angle is crucial to ensure uniform assembly gaps. Unevenness, missing material, and overheating defects on the beveling surface are strictly prohibited. For weld holes and chamfers, the radius of the weld hole fillet should be no less than 15mm to avoid stress concentration caused by sharp corners. End chamfers and locking transitions should be smooth, without sharp notches. Regarding thermal deformation control, continuous long cuts are performed using segmented cutting and intermittent cooling. For thin-walled rectangular pipes, power is reduced and speed is increased to prevent burn-through and deformation. The laser must not remain in the same area for an extended period to avoid localized overheating and warping.Cutting quality acceptance shall comply with general standards. In terms of dimensional deviation, the length deviation shall be controlled within ±1.0mm, the perpendicularity of the cut shall not exceed 0.05 times the plate thickness and not exceed 1.5mm, and the perpendicularity of the end face to the component axis shall not exceed 1.0mm. The quality requirements for the cut surface are as follows: the surface shall be smooth, without obvious step marks, deep cut marks, cracks, delamination, slag inclusions, notches, or chipping defects, the slag shall be thin and easy to remove, and hard slag shall not be allowed. The surface roughness shall meet Ra≤25μm. The appearance requirements are as follows: there shall be no overheating, severe oxidation and discoloration, no arc craters, holes, or missing parts, and burrs and slag must be completely cleaned. At the same time, the following prohibitions are clearly stated: it is strictly forbidden to use gas cutting or laser cutting to arbitrarily enlarge holes to replace high-strength bolt holes; it is strictly forbidden to cut on cracks, interlayers, or severely corroded parts of the base material; it is strictly forbidden to forcibly break the component after cutting to prevent tearing of the base material. Finished product inspection requires checking length, angle, bevel angle, blunt edge, hole position, hole diameter, hole spacing, cut perpendicularity, cross-sectional quality, component deformation, and appearance and burr removal. Laser drilling is suitable for the web and flange plates of finished H-beams, and the walls of finished rectangular and square steel tubes. It can perform high-precision drilling operations such as ordinary bolt holes, high-strength bolt holes, process holes, and weld holes. Drilling operations require components made of structural steel such as Q235 and Q355, with no severe rust, oil, or oxide scale on the surface. Components must be straightened and leveled before drilling; components with excessive deformation must not be drilled. The positioning accuracy of the processing equipment must not exceed ±0.1mm, and the repeatability must not exceed ±0.05mm. Programming must be based on construction drawings, Tekla, or DSTV CNC files exported from CAD. In the process preparation stage, the drawings are first reviewed to verify the hole diameter, hole position, hole spacing, hole group position, hole edge distance, and distance from the hole to the end. It is clear that gas cutting to enlarge holes and arbitrary modification of holes are strictly prohibited for high-strength bolt holes. In the workpiece clamping stage, the components are rigidly pressed and reliably positioned to prevent movement during drilling. The support is uniform to avoid vibration and hole misalignment caused by suspension. Oxygen or nitrogen is selected as the auxiliary gas, and the pressure is controlled between 0.6 and 1.2 MPa, adjusted according to the plate thickness. In terms of parameter settings, the laser power is selected between 6 and 15 kW according to the plate thickness. The pulse frequency, peak power, and blowing sequence are executed according to the equipment process library. When processing thin-walled tubes, care should be taken to avoid perforation burst points and burn-through of the back side.The laser drilling process involves workpiece loading, positioning and clamping, program invocation, followed by machine tool edge finding and alignment, automatically aligning the steel end face with the center line to ensure the hole position is consistent with the component axis, completing the first trial drilling, measuring the hole diameter, hole spacing, and hole center position, and checking the hole wall quality and back-side ablation. Only after passing the inspection can batch processing begin. Formal drilling follows the program sequence, prioritizing the machining of the web plate followed by the flanges, and prioritizing symmetrical hole layout. When drilling rectangular steel pipes, care should be taken to avoid single-sided high heat that could cause pipe wall deformation and elliptical holes. For thin-walled pipes, short pulses and low energy are used for drilling. When drilling H-beams, care should be taken to avoid the stress concentration area at the junction of the flange and web plate. The hole edge distance generally meets the design requirement of not less than 1.5 times the hole diameter. After drilling, slag removal and deburring are completed, and all slag and burrs at the hole opening are removed. Chamfering of the hole opening is performed as needed to avoid sharp edge tearing. Then, marking and inspection are carried out, checking the hole position, hole diameter, and hole spacing group by group. Qualified components are marked, and unqualified components are isolated for rework. The quality control requirements for laser drilling are clearly defined. Regarding hole diameter accuracy, the diameter deviation of Class A and Class B high-strength bolt holes is controlled within +0.18 to 0 mm, meeting the H12 grade accuracy requirements. The diameter deviation of Class C ordinary bolt holes is controlled within +0.5 to 0 mm, and flared, elliptical, or conical holes are not permitted. Hole position and spacing deviations comply with the "Standard for Acceptance of Construction Quality of Steel Structures" GB50205. The spacing deviation within the same group should not exceed ±0.5 mm, the spacing deviation between groups should not exceed ±1.0 mm, the deviation from the hole center to the component edge should not exceed ±1.0 mm, and the overall offset of the hole group should not exceed ±1.5 mm. Hole wall quality requirements include vertical and smooth walls, free from obvious stripes, pits, and cracks, with no severe ablation, slag, or burrs on the back side. The verticality deviation should not exceed one percent of the plate thickness and should not exceed 2 mm. Appearance requirements include no cracks, missing edges, or chipped edges at the hole opening. Excessive local discoloration, deformation, or warping of components due to laser heat is prohibited. Randomly applying laser spots or testing the light on the component surface is strictly forbidden. The finished product inspection items include checking the hole diameter with plug gauges or calipers, checking the hole spacing and position with steel rulers, templates, and total stations, checking the hole verticality and hole wall appearance, checking the deformation and warping of the components, and forming a drilling inspection record, which is archived with the component data.

[0058] The assembly and robotic welding process is the core forming process of the components. It adopts a parallel operation mode with partitioned operation. The assembly of stiffening plates and steel brackets is separated and carried out simultaneously at independent workstations. After the stiffening plates are assembled with the main components, they are sent to the automatic welding workstation 43. After the steel brackets are assembled with the main components, they are sent to the collaborative welding robot 22 workstation. Both welding workstations are equipped with positioners, which can clamp the components and automatically rotate and adjust them to the optimal flat welding posture. The automatic welding workstation 43 is responsible for completing the batch standardized stiffening plate welding operation to ensure the efficiency of batch processing. The collaborative welding robot 22 is responsible for completing the welding operation of complex steel bracket nodes to adapt to the processing requirements of complex nodes. At the same time, the flipping machine 44 can cooperate to complete the overall displacement of the components to ensure the accuracy of assembly and welding, realizing the balance between efficient welding of standardized components and flexible welding of complex nodes.

[0059] The robotic welding process for stiffening plates and corbels of finished rectangular steel pipes and H-beams is applicable to finished rectangular steel pipes and H-beams made of Q235B and Q355B materials. It covers the corner joint and T-joint welding of external stiffening plates to the component body, and the T-joint and cross joint welding of steel corbels to the component body. It can realize all-position robotic automatic welding of the connection between the two types of components and stiffening plates and corbels, and takes into account the welding needs of thin-walled and thick plates. During the construction preparation phase, the requirements for components and materials must be clearly defined. The materials of finished rectangular steel pipes, H-beams, stiffening plates, and corbel plates must be consistent. Complete quality assurance certificates and re-inspection reports must be provided upon arrival on site. Welding of different materials is strictly prohibited. Before welding, components must be straightened and leveled. Rectangular steel pipes must be free from bending and elliptical deformation, and H-beams must be free from flange tilting, web bulging, and excessive twisting. Component surfaces must be free from obvious damage and corrosion. Welding joints and the surrounding 50mm area must be ground and cleaned thoroughly to remove rust, oil, scale, paint, and moisture, exposing the metallic luster to avoid affecting weld fusion quality. MAG gas shielded welding will be used. The welding wire used will be the ER50-6 type, suitable for both Q235 and Q355. The shielding gas will be a mixture of 80% argon and 20% carbon dioxide. Welding materials must be within their expiration date and stored separately in a dry, ventilated environment, protected from moisture and dust. The model and batch number must be verified before use. Regarding equipment and tooling requirements… The process employs six- or seven-axis industrial robots, equipped with dual-station positioners or tilting frames, and a MAG gas shielded welding system. The robots feature automatic arc length control, oscillating welding, multi-layer multi-pass welding, and breakpoint welding capabilities to ensure welding stability. Custom-designed fixtures are used based on the component's shape, requiring sufficient rigidity and precise positioning to effectively secure the components, stiffeners, and brackets, ensuring no loosening or shifting during welding and preventing deformation. A welding torch cleaning and wire-cutting mechanism and a cooling system are also provided to ensure continuous welding. Inspection tools such as feeler gauges, calipers, and weld gauges are prepared for checking assembly gaps and weld dimensions. Regarding personnel requirements, robot programmers and operators undergo professional training and are familiar with robot operation procedures, welding parameter settings, and the welding characteristics of the two types of components. Certified welders are on-site to handle the assembly, tack welding, and weld repair of stiffeners and brackets, ensuring the tack welding quality meets requirements. The general process flow of this technology is as follows: component loading, tooling positioning and clamping, stiffener and bracket assembly, tack welding, robot program calling and teaching, robot automatic welding, post-weld slag and spatter removal, post-weld correction, appearance and dimensional inspection, non-destructive testing as needed, and marking and handover.The requirements for assembly and tack welding are clearly defined. The position, elevation, and overhang length of stiffeners and brackets must be strictly in accordance with the design drawings, and the deviations must meet the requirements of the "Standard for Acceptance of Construction Quality of Steel Structures" GB50205. Rectangular steel pipe brackets must be perpendicular to the pipe axis, and H-beam steel brackets must be tightly fitted to the web and flanges. The local gap of the joint should not exceed 1mm and the gap should be uniform. Forced assembly is strictly prohibited to avoid generating excessive internal stress that may affect the welding quality. Tack welding uses the same grade of welding wire as the formal welding. The length of the tack weld should not be less than 30mm, the spacing should be 100 to 150mm, and the height of the weld leg should not be less than half of the formal weld leg. Tack welds should be free of defects such as cracks, porosity, and slag inclusions. If defects are found, they should be removed and re-welded immediately. Tack welds should avoid the corners, stress concentration areas, and bevel edges of components. Excessively long tack welds should be ground into a gentle slope to avoid stress concentration during formal welding. For components with different plate thicknesses, the process is equipped with differentiated welding parameters. For plates 6 to 10 mm thick, a 1.2 mm diameter welding wire is used, with the welding current controlled at 240 to 280 A, the welding voltage at 28 to 32 V, the welding speed at 40 to 60 cm / min, and the shielding gas flow rate at 18 to 22 L / min. For plates 10 to 20 mm thick, the welding current is adjusted to 280 to 320 A, the welding voltage to 30 to 34 V, the welding speed to 35 to 50 cm / min, and the shielding gas flow rate to 20 to 25 L / min. For multi-layer welding of thick plates, the welding... The current should be controlled between 260 and 300A, the welding voltage between 29 and 33V, the welding speed between 30 and 45cm / min, and the shielding gas flow rate between 20 and 25L / min. Supplementary requirements specify that fillet welds should be welded using a slanted or triangular slant method, with the slant amplitude adjusted according to the weld leg size to ensure good weld fusion and uniform weld leg. For plates thicker than 16mm or welded in low-temperature environments below 5℃, preheating should be performed according to specifications, with a preheating temperature of 80 to 150℃. The interpass temperature should be controlled to be no greater than 250℃. For multi-layer, multi-pass welding, each weld should be thoroughly cleaned of slag before proceeding to the next weld to avoid slag inclusion defects. The welding sequence is controlled differently according to the component type. For finished rectangular steel pipe components, symmetrically arranged stiffeners are welded symmetrically and alternately to avoid local concavity and elliptical deformation of the steel pipe caused by continuous welding on one side. When welding the corbel, the connection between the corbel web and the rectangular steel pipe is welded first, followed by the connection between the corbel flange and the steel pipe. For the same corbel, the inner side is welded first, followed by the outer side, and the short seam is welded first, followed by the long seam. Long seams are welded in sections with back welding or skip welding to reduce the accumulation of thermal deformation and avoid exceeding the straightness standard of the steel pipe. For H-beam components, the transverse stiffeners are welded first at the web connection, followed by the flange connection. The longitudinal stiffeners are welded symmetrically and alternately to control the lateral bending of the H-beam. When welding the corbel, the connection between the corbel web and the H-beam web is welded first, followed by the connection between the corbel flange and the H-beam flange. Continuous welding on one side is avoided to prevent the H-beam flange from tilting and the web from bulging. Multi-layer and multi-pass welding is used at the junction of the corbel and the H-beam flange and web to ensure sufficient weld fusion and avoid stress concentration areas.The welding quality requirements are clearly defined. In terms of common requirements, the weld appearance should be uniform and smooth, without obvious abrupt changes in ripples, weld beads, pits, or fatal defects such as cracks, lack of fusion, burn-through, dense porosity, and slag inclusions. The weld leg dimensions should conform to the design drawings, with deviations controlled within 0 to +2mm, and should not be too small. For fillet welds, the two weld legs should be basically symmetrical, with a smooth transition to the base metal. The undercut depth should not exceed 0.5mm, the continuous undercut length should not exceed 100mm, and the cumulative undercut length should not exceed 10% of the total weld length. Porosity and slag inclusions are also acceptable. After thoroughly removing defects such as incomplete fusion, re-welding is performed. Cracks must be repaired after the cause is identified. Regarding the specific requirements for each component, rectangular steel pipes should not have obvious elliptical deformation or local depressions after welding, and the straightness deviation should not exceed one-thousandth of the component length and not exceed 5mm. After welding H-beams, the verticality deviation of the flange plate should not exceed one-two-fiftieth of the section height and not exceed 5mm. The straightness of the web plate and the straightness of the component should meet the requirements of the "Standard for Acceptance of Construction Quality of Steel Structures" GB50205, and there should be no flange tilting or web bulging defects. In the post-weld treatment stage, immediately after welding, remove spatter, slag, and weld beads from the weld surface and surrounding area to ensure the surface of the component is clean. Burrs at holes and bevels should be ground smooth. Check the welding deformation of the component. Cold straightening should be used for parts that exceed the tolerance. When hot straightening is required, the temperature should be controlled between 600 and 800℃. Overheating is strictly prohibited. After straightening, direct cooling with water is strictly prohibited. According to design requirements and specifications, magnetic particle testing or ultrasonic testing should be carried out on important nodes and stress welds. Only after passing the test can the next process be carried out. During the finished product acceptance process, dimensional acceptance requires that the position, elevation, and overhang length of stiffeners and corbels, as well as the external dimensions, straightness, and perpendicularity of rectangular steel pipes and H-beams, all conform to the design drawings and the requirements of the "Standard for Acceptance of Construction Quality of Steel Structures" GB50205. Weld acceptance requires that the appearance quality and weld leg dimensions be qualified, the non-destructive testing report meet the requirements, and there be no defects exceeding the standard. Document acceptance requires that welding records, robot program records, tack welding records, slag removal records, non-destructive testing reports, and inspection records be complete, traceable, and archived with the component documents. Identification acceptance requires that qualified components be clearly marked with the component number, material, welding date, and inspection status, while unqualified components are isolated for repair and are strictly prohibited from entering the next process.

[0060] The automated quality inspection and surface treatment process is the final stage of component manufacturing. It adopts a "test first, process later" process logic. The precast components that have been welded are first sent to the inspection station, where a 3D laser scanner 51 performs a full-size non-contact scan. The collected point cloud data is automatically compared with the standard design model in the central control system to complete the fully automated inspection and qualification judgment of dimensional accuracy, geometric tolerances, and weld appearance. The precast components that pass the inspection are sent to the closed sandblasting room 52 to remove the oxide scale, welding slag, and rust layer on the surface of the components through shot blasting. At the same time, shot recycling and centralized dust treatment are realized, taking into account the environmental protection of the operation. The unqualified precast components are automatically diverted to the rework station to avoid ineffective surface treatment operations and ensure the quality of the finished product and the surface anti-corrosion performance.

[0061] The 51-step inspection process for finished rectangular steel pipes and H-beams using a 3D laser scanner is designed for high-precision, full-size inspection of these components. Before inspection, preparatory work is crucial. This involves confirming requirements and the proposed solution, defining the inspection objectives, including dimensional accuracy, geometric tolerances, weld contours, assembly interface compatibility, and deviations from the design model. The required accuracy for finished components is ±0.5 to 2 mm, while critical components and interfaces require an accuracy of no more than ±1 mm. The specifications, length, quantity, placement, material, and surface condition of the components are also confirmed. A corresponding scanning plan is then developed, determining the scanning equipment, the number and location of scanning stations, target placement, scanning parameters, coordinate system, post-processing software, and report templates. Following this, site and environmental preparation is conducted, clearing obstructions and debris around the components to ensure a smooth inspection. Ensure the scanning path and field of view are unobstructed. Place components stably on wooden blocks or supports to avoid vibration. Support long components in sections to reduce the impact of self-weight deformation. In terms of environmental control, avoid direct sunlight and specular reflection. For metal components, appropriately reduce scanning power or apply matte markings. Maintain stable ambient temperature to avoid thermal expansion and contraction caused by temperature differences. Keep away from machinery and vehicles. Keep the site stationary during scanning. Finally, complete the coordinate system and target layout. Establish a global coordinate system that is consistent with the design BIM or CAD model. At the same time, establish a local coordinate system with the component end face, center line, and reference plane as the origin to facilitate dimension extraction. Use highly reflective spherical or planar targets and coded targets. Arrange no less than 4 targets for each component segment, evenly distributed at both ends and the middle. Denser targets are used at key interfaces and variable cross-sections. The target center positioning error should not exceed ±0.2mm. During the on-site scanning implementation phase, the scanning parameters were first set. The point spacing for critical areas was set to 0.5 to 1 mm, and for the main body area, it was set to 1 to 2 mm. For features such as cross-sections, welds, and holes, a fine mode was selected; for the main body length, straightness, and overall shape and position, a standard mode was selected. Exposure and power were adjusted: power was reduced for metal surfaces to avoid overexposure and point loss; normal power was used for matte or painted surfaces. Station placement and scanning paths followed the principle of full coverage, ensuring no blind spots or obstructions on any surface of the component. The overlap rate of each station was no less than 30% to facilitate data stitching. Long components were scanned in segments, with an overlap of no less than 500 mm between segments. Ports, bevels, bolt holes, welds, etc., were also scanned. For variable cross-section areas, localized dense scanning is performed on H-beams or rectangular tube components. A typical station layout includes one station on the front, one on the back, and one on each end. For long components, one to two additional stations are added in the middle. When scanning handheld, the device moves at a constant speed along the length of the component to ensure continuous point cloud coverage. Densification is achieved at corners and interfaces. In the data acquisition and quality control phase, after equipment initialization, calibration, and standardization, the target is scanned first to establish a baseline. Then, the component is scanned along the path. The integrity of the point cloud is previewed in real time. Blind spots, missing areas, and key features are scanned to fill in gaps. The point cloud density is checked to be uniform, without voids, flying spots, or obvious noise. The target is clearly identifiable, the stitching preview error is no more than ±1mm, and key features are completely captured.In the point cloud data post-processing stage, preprocessing is first performed to remove flying points, isolated points, and environmental noise, retaining the effective point clouds of the components. Coarse registration is completed based on targets, followed by fine registration based on features. The global stitching error is controlled to no more than ±1mm for key components and no more than ±2mm for general components. Filtering and segmentation are then performed to separate the component point clouds from the background, extracting sub-point clouds of the component body, welds, holes, etc. Interpolation fitting is performed for missing areas to smooth the point clouds while preserving feature details. Subsequently, 3D modeling and benchmark alignment are carried out. Based on the geometric features of the components fitted from the point cloud, solid or surface models are generated. The scanned model is then best fitted and aligned with the design BIM or CAD model, unifying the coordinate system. Finally, dimensional and geometric deviation analysis is performed. For rectangular steel pipes, key dimensions such as length, width, height, wall thickness, diagonal difference, end face perpendicularity, inner and outer fillets, hole center distance, and hole diameter are extracted. For H-shaped... Key dimensions such as length, height, flange width and thickness, web thickness, flange perpendicularity, web flatness, cross-section center deviation, bevel angle, and weld width and height are extracted from the steel. For form and position tolerance inspection, a centerline is fitted along the component axis to calculate the maximum deviation values ​​of straightness and curvature. A reference surface is fitted to the flange and web surfaces to calculate flatness deviation. The angular deviation between the end face and the axis, and between the flange and the web, is detected to obtain perpendicularity and angular deviation. The relative torsional angle of the two end sections is calculated to obtain torsion. The center position deviation of bolt holes and interfaces is detected. Simultaneously, the deviation distribution of the entire component is visually displayed through 3D chromatograms. Cross-sections at any position are compared with the designed and actual sections to complete deviation statistics. For welds, corresponding point clouds are extracted, weld contours are fitted, and defects such as weld leg height, weld width, reinforcement height, bevel angle, undercut, and porosity are measured. Comparison with process requirements is used to determine whether the welds are qualified. Upon completion of the inspection, a complete inspection report will be output, including project and component information, inspection results, conclusions, and attachments. The inspection results will include a comparison table of measured and design values ​​for key dimensions, geometric tolerance inspection results, 3D deviation chromatograms, cross-sectional comparison diagrams, enlarged views of key features, and weld inspection results. Deliverables will include a paper or electronic inspection report, a point cloud model, a 3D solid model, and a deviation data table. This process is equipped with quality control and accuracy assurance measures. Before scanning, the equipment is calibrated using standard blocks or calibration plates to ensure equipment accuracy. Targets are evenly distributed and accurately positioned, and splicing errors are strictly controlled. Secondary scanning verification is conducted for key components or out-of-tolerance areas. Inspection personnel undergo professional training and are familiar with equipment and software operation, as well as steel structure inspection standards. The inspection process strictly adheres to relevant specifications such as the "Standard for Acceptance of Construction Quality of Steel Structures" (GB50205) and the "Technical Specification for 3D Laser Scanning Measurement."

[0062] Shot blasting for rust removal from finished rectangular steel pipes and H-beams is suitable for finished rectangular steel pipes, square pipes, and H-beams, with lengths ranging from 3 to 12 meters. It is compatible with through-feed shot blasting machines and removes oxide scale, rust, oil, and welding slag from the surface of the components, improving the adhesion of subsequent coatings. The process principle involves using a high-speed rotating impeller to propel steel shot, steel wire segments, and abrasive particles at high speed onto the component surface. Through impact and grinding, rust, oxide scale, welding slag, and burrs are removed, while simultaneously creating a uniformly rough anchor pattern depth, improving the adhesion of paint or anti-corrosion coatings. Regarding raw material and equipment requirements, S390 to S550 steel shot is used for rough cleaning and removal of thick oxide scale. 0.6 to 1.2 mm steel wire segments enhance cutting force and improve surface roughness. Sharp-edged abrasive assists in cleaning dead corners and weld areas. The recommended ratio is 60% steel shot, 30% steel wire segments, and 10% sharp-edged abrasive. The hardness of the abrasive should be controlled at 40 to 50 HRC to avoid low efficiency due to excessive softness and excessive breakage due to excessive hardness. The shot blasting equipment adopts a through-type roller conveyor shot blasting machine, equipped with 4 to 8 blasting heads arranged vertically and horizontally. It is also equipped with a dust removal system, an abrasive circulation and sorting system, and a blowing system. In the component pretreatment stage, obvious oil and grease on the component surface are removed. If necessary, alkaline washing or solvent wiping is used. Temporary lifting lugs are cut off, weld points are ground flat, component deformation is checked, and jamming and collision with the shot blasting chamber are prevented. The process flow is as follows: component loading, roller conveyor, shot blasting for rust removal, dust removal by blowing, unloading inspection, and pre-coating protection. During loading and conveying, components are placed stably on the roller conveyor. The web of H-beams is vertical and the flanges are horizontal. Rectangular tubes are not stacked and are passed through one piece at a time. The conveying speed is controlled between 0.8 and 1.8 m / min. For thick rust and heavy oxide scale, a low speed is used, while for light rust, the speed can be increased appropriately. In terms of shot blasting parameter control, the shot blasting head current is controlled between 75% and 90% of the rated current. A single pass of the component can achieve full coverage. If necessary, it can be passed back and forth once. The abrasive flow rate is automatically adjusted according to the number of shot blasting heads to ensure continuous and uniform blasting. A slight negative pressure is maintained in the shot blasting chamber to prevent dust from overflowing. After shot blasting, high-pressure air is used to blow away residual steel shot and floating dust to ensure that there is no residual abrasive or floating dust on the surface before proceeding to the next coating process. Regarding quality standards and inspection, the surface cleanliness level must reach Sa2.5 (near-white), free of visible grease, dirt, scale, rust, and coatings. Surface residue should only consist of slight, dotted or streaky spots; low-level cleanliness (Sa1 or Sa2) is not permitted for shipment. For surface roughness, conventional paint coatings require 40-80 μm, while thick fire-retardant coatings or heavy-duty anti-corrosion coatings require 60-100 μm, measured using roughness comparison samples or an electronic roughness meter. Visual inspection requires no missed shot blasting, no exposed substrate, and no obvious impact dents. Rust removal should be uniform at corners, ends, and weld areas, without excessive shot blasting leading to thinning, deformation, or flange ripples. For finished product protection, primer should be applied within 4 hours of shot blasting, and no more than 2 hours in humid environments. Avoid direct hand contact with the rust-removed surface to prevent rust recurrence. Components not coated in time should be covered with a rainproof and moisture-proof protective layer.

[0063] The intelligent logistics and collaborative management process is a supporting process for the collaborative flow of the entire production line. The production line adopts a combined conveying mode of RGV mother-daughter carts 11 and AGV automated guided vehicles 12. The RGV mother-daughter carts 11 run along fixed tracks that run through the main processes, and are responsible for the long-distance and precise transfer of large-sized and heavy main materials between the main process units, ensuring the stability of the transportation of heavy-load materials. The AGV automated guided vehicles 12 rely on flexible navigation paths to be responsible for the flexible transfer of scattered small materials between the raw material processing unit 2 and the welding unit. They can be scheduled without occupying the main track, relieving the transportation pressure on the main line. Both types of equipment are uniformly scheduled by the central control system. The central control system realizes real-time perception of the status of the entire production line through full-dimensional data acquisition, digital twin physical modeling, and fusion of multi-source business and equipment data. It automatically completes production scheduling, process adjustment and instruction issuance, and realizes rapid response to faults through abnormal alarms, ensuring seamless connection and collaborative operation between various processes.

[0064] In this embodiment, three typical components from a prefabricated steel structure residential project were selected for measurement and balance calculation. Component 1: BH350×150×8×16, length 6m, weight 0.4t; Component 2: RHS160×500×12, length 2m, weight 0.58t; Component 3: RHS160×500×20, length 9m, weight 1.9t. Calculations showed that the production line balance rates for the three components were 86.7%, 84%, and 80.3%, respectively; the balance loss rates were 13%, 16%, and 19.7%, respectively; and the production line smoothness indices were 5.89, 4.76, and 8.27, respectively. These data indicate that the production line has a relatively balanced distribution of operation time across processes, small load differences between workstations, effectively avoiding process backlog or waiting, and ensuring smooth overall operation.

[0065] Based on the above cycle time calculations and considering the annual working hours (250 working days, 16-hour shifts per day), the annual single-process production capacity for the three types of components is as follows: laser cutting process: 17,200–79,700 tons; automatic assembly process: 13,400–24,300 tons; automatic welding process: 22,900–118,900 tons; collaborative welding process: 14,500–35,200 tons; sandblasting process: 11,400–27,100 tons. Considering the combined production proportions of the three components (30% for component 1, 30% for component 2, and 40% for component 3), the overall annual production capacity of this automated production line is approximately 17,500 tons. This capacity level can fully meet the large-scale, batch manufacturing needs of lightweight steel components for prefabricated steel structure residential projects.

[0066] This production line achieves 100% automation in key processes (cutting, welding, logistics, and inspection) through full-process automation and a 60% self-owned rate for robots and production control software. Compared to the traditional manual production model, it reduces manpower by approximately 50%, increases production efficiency by approximately 40%, and lowers overall manufacturing costs by approximately 30%. Based on an annual production of 17,500 tons of steel components and an estimated reduction in processing cost of approximately 800-1200 yuan per ton, annual cost savings are estimated at approximately 14-21 million yuan. Considering the total investment in production line equipment and IT (estimated at approximately 30-40 million yuan based on a typical configuration), the expected investment payback period is 2-3 years. Furthermore, improved product quality stability and increased material utilization (reuse of surplus materials) further enhance the company's profitability and market competitiveness.

[0067] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. An automated production line for lightweight steel components in prefabricated steel structure residential buildings, characterized in that, The system includes a central control system, an automatic conveying system (1), and a raw material processing unit (2), a laser cutting unit (3), a robotic welding unit (4), and a shot blasting unit (5) arranged sequentially along the material conveying direction. The raw material processing unit (2) is used to stack raw materials and connect the cut residue. The laser cutting unit (3) is used to cut, open, and bevel the raw materials. The robotic welding unit (4) is used to automatically weld the raw materials to form prefabricated parts. The shot blasting unit (5) is used to perform quality inspection and surface shot blasting rust removal on the prefabricated parts. The automatic conveying system (1) is set between each unit and is used to automatically transfer materials between each unit. The central control system is used for production scheduling. It stores a database of processing requirements and sends processing information to the raw material processing unit (2), the laser cutting unit (3), the robotic welding unit (4), and the shot blasting unit (5).

2. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 1, characterized in that, The automated conveying system (1) includes: RGV mother-daughter vehicle (11), which moves along a preset track and is used to transport raw materials or prefabricated parts between processing units; An AGV (Automated Guided Vehicle) (12) moves along a preset path to transport prefabricated parts between the raw material processing unit (2), the laser cutting unit (3), and the robotic welding unit (4).

3. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 1, characterized in that, The raw material processing unit (2) includes: Raw material storage yard (21), which is used to store raw materials to be processed; A collaborative welding robot (22) is set up next to the raw material stockpile (21) for butt welding of the cut scraps.

4. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 1, characterized in that, The laser cutting unit (3) includes: Raw material storage warehouse (31) is located at the entrance end of the laser cutting unit (3) and is used to temporarily store raw materials; Laser profile cutting machine (32), the laser profile cutting machine (32) is set on the discharge side of the raw material vertical warehouse (31) and is used to cut, open and bevel the raw material; Semi-finished product storage unit (33) is located on the discharge side of the laser profile cutting machine (32) and is used to temporarily store the cut semi-finished products.

5. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 4, characterized in that, The laser cutting unit (3) also includes: Steel transfer machine (34), which is set on one side of the laser profile cutting machine (32), is used to receive raw materials that do not require secondary processing after cutting; The output roller conveyor is connected to the steel transfer machine (34) and is used to output and store the raw materials that have been cut and do not require secondary processing in the steel transfer machine (34).

6. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 1, characterized in that, The robotic welding unit (4) includes a stiffener assembly area (41), a steel bracket welding area (42), an automatic welding workstation (43), and a collaborative welding robot (22). The stiffener assembly area (41) and the steel bracket welding area (42) are respectively located at different workstations of the robot welding unit (4) and are used for the assembly of stiffeners and steel brackets respectively. The automatic welding workstation (43) is located on the discharge side of the stiffener assembly area (41) and is used to automatically weld the raw materials of the assembled stiffener. The collaborative welding robot (22) is located in the welding area (42) of the steel bracket component and is used to weld the raw materials of the assembled steel bracket.

7. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 6, characterized in that, The robotic welding unit (4) also includes a positioner, which is located at the automatic welding workstation (43) and the collaborative welding robot (22) and is used to clamp and rotate the raw material to a preset welding posture.

8. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 1, characterized in that, The shot blasting detection unit (5) includes: A three-dimensional laser scanner (51) is set at the inspection station and is used for non-contact inspection of the dimensions and geometric tolerances of the prefabricated parts; A sandblasting room (52) is set on the discharge side of the three-dimensional laser scanner (51) and is used to perform shot blasting and rust removal on the surface of the qualified precast parts.

9. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to claim 1, characterized in that, The central control system includes a data acquisition module, a data modeling module, a data fusion module, a data calculation module, and a data subscription and message notification module; The data acquisition module is used to collect the operating status data of each unit and device; The data modeling module is used to construct a physical model of the device based on the collected data; The data fusion module is used to fuse and analyze the collected operational status data and business data; The data calculation module is used to generate control commands based on the analysis results; The data subscription and message notification module is used to send control commands to each unit and device, and to provide alarm notifications for abnormal states.

10. The automated production line for lightweight steel components of prefabricated steel structure residential buildings according to any one of claims 1 to 9, characterized in that, The raw materials include rectangular steel pipes, H-beam steel components, and reinforcing steel plates.

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