A large special-shaped steel component assembling and welding device

Abstract

The application discloses a large special-shaped steel component assembling and welding device, which comprises a support array and a control cabinet arranged along a component theoretical line shape, and further comprises an independent rigid linear reference, wherein the support array is a plurality of force-position integrated active support mechanisms, and each of the force-position integrated active support mechanisms is movably arranged on a calibrated measuring base along the length direction of the component. The application solves the inherent defects of the traditional welding jig reference and support coupling and the precision drift caused by the bearing deformation by the decoupling design of the independent rigid linear reference and the support array; the double-constraint control formed by the force measuring unit and the displacement sensor in series in the force transmission main line can accurately identify and eliminate the virtual support empty defect caused by the self-weight sag of the plate, so that the linear precision in the assembling stage is ensured on the basis of the real and effective bearing, and the assembling linear consistency of the special-shaped steel components such as the bending and torsion and the variable cross-section is significantly improved.

Description

Technical Field

[0001] This invention relates to the field of steel structure manufacturing equipment technology, and in particular to a large-scale irregular steel component assembly and welding device. Background Technology

[0002] In large-span building and bridge engineering, curved and twisted box-shaped, variable cross-section, and spatial curved surface irregular steel components are mostly formed by welding multiple plates together after they are assembled, positioned, and tack-fixed. The linear accuracy of the assembly stage directly determines the quality of the finished component and the accuracy of on-site assembly.

[0003] For example, CN110369941A discloses an H-beam steel component assembly jig and a method for manufacturing H-beam steel components that can effectively reduce welding deformation. The jig includes a left upright plate, a right upright plate, a positioning support, and a base. The base consists of two parallel I-beam steel beams. The left upright plate, the right upright plate, and the positioning support are vertically mounted on the base. The left and right upright plates are each fitted with an adjustment plate that can preset the anti-deformation amount of the flange. The upper end of the adjustment plate is hinged to the upper edge of the opening of the left or right upright plate, and the lower end of the adjustment plate is connected to the lower edge of the opening of the left or right upright plate by bolts. The adjustment angle between the adjustment plate and the left or right upright plate is 2-3.5°. The adjustment plate is equipped with an electromagnetic chuck.

[0004] Existing billet assembly and welding equipment mostly adopts fixed-elevation or integral lifting rigid support jigs, using the support surface as the positioning reference. This has an inherent defect of coupling the reference and support functions. The processing error and stress deformation of the support structure will be directly transmitted to the component's linear error, and the accuracy of the reference lacks independent and stable guarantee. At the same time, large irregular steel components do not form a closed section during the billet assembly stage, resulting in weak bending stiffness. Under the action of self-weight, deflection occurs between adjacent support points, and the actual linearity deviates from the theoretical linearity. Fixed-elevation supports cannot detect this deviation and do not have the ability to adjust it point by point. The deviation is locked during billet assembly, forming an initial geometric defect. Meanwhile, during the welding process, weld shrinkage and angular deformation are superimposed on the initial defects, and the stiffness of the component continues to change with the welding progress, resulting in an imbalance of forces at each support point, causing virtual support to fall off or local overload, inducing additional stress and uneven rebound, and the finished product's linear deviation is highly random and batch consistency is poor; existing equipment lacks the ability to detect support reaction force in real time, and adjustments rely on manual experience, the process cannot be reproduced, and it can only rely on post-weld hydraulic cylinder pressure and flame straightening as passive remedies, with limited straightening effect and easy damage to the base material, making it impossible to achieve dynamic control of the linearity throughout the welding process.

[0005] In summary, there is an urgent need to address the technical problems in this field, such as the coupling of positioning reference and support functions, the lack of integrated force and position perception of support, the inability to independently and dynamically adjust point by point with the welding station, and the inability to actively correct deviations due to passive adaptation, in order to achieve the active establishment of theoretical line shape in the billet assembly stage and the stable maintenance throughout the welding process. Summary of the Invention

[0006] One objective of this invention is to provide a welding device for assembling large irregular steel components. This invention can effectively improve welding quality while ensuring welding efficiency.

[0007] According to an embodiment of the present invention, a large irregular steel component assembly and welding device includes a support array and a control cabinet arranged along the theoretical line of the component, and also includes an independent rigid linear reference. The support array consists of several force-position integrated active support mechanisms, each of which can be independently moved along the width direction of the component and arranged on a calibrated measuring base. The independent rigid linear reference is fixedly arranged on the calibrated measurement base, independently of the support array, and does not have any bearing contact with the component to be processed throughout the process. It is used to provide the absolute coordinate reference of the theoretical line of the component and to provide the force-position integrated active support mechanism for calibrating the starting elevation. The force-position integrated active support mechanism comprises, from bottom to top, a base flange, a support X-axis traveling assembly, a servo drive unit, a series force measuring unit, a hinged joint, and a normal contact head. The base flange is anchored to the measuring foundation. The fixed end of the support X-axis traveling assembly is mounted on the base flange, and the moving end carries the servo drive unit upwards. The cylinder of the servo drive unit is fixedly mounted on the upper part of the moving end of the support X-axis traveling assembly, and the output end is vertically upward. The series force measuring unit is connected in series between the output end of the servo drive unit and the normal contact head, and is located in the main force transmission path of the component's support reaction force. The normal contact head is connected to the series force measuring unit through the hinged joint, and the working surface of the normal contact head corresponds to the local normal arrangement of the component. The servo drive unit integrates a displacement sensing unit. The signal output terminals of the series force measuring unit and displacement sensing unit are both connected to the control cabinet, and the control terminals of the X-axis walking component and servo drive unit are controlled by the control cabinet.

[0008] Preferably, it also includes a feeding mechanism, wherein the control cabinet is signal-connected to the controller of the feeding mechanism; the feeding mechanism includes a three-axis moving assembly, and the moving terminal of the three-axis moving assembly is equipped with a feeding fixture assembly for clamping the plate to be welded.

[0009] Preferably, it further includes a welding mechanism, wherein the control cabinet is signal-connected to the controller of the welding mechanism; the welding mechanism includes a Y-axis moving component, and at least two welding end X-axis shifting components are installed at the moving end of the Y-axis moving component, and a welding robot arm component is installed at the moving end of each welding end X-axis shifting component; the two welding robot arm components are configured to move synchronously along the weld seam to achieve symmetrical synchronous welding of the component on both sides.

[0010] Preferably, a side plate positioning mechanism is provided on one side of the force-position integrated active support mechanism. The side plate positioning mechanism includes a side plate X-direction adjustment component. A swing component that swings around the length direction of the component is installed on the upper part of the moving end of the side plate X-direction adjustment component. A fixed frame is fixedly connected to the swing output end of the swing component. A side plate clamping component is installed on the surface of the fixed frame. A plate thickness limiting clamping component is provided on the clamping side of the side plate clamping component.

[0011] Preferably, the independent rigid linear reference adopts a ground-fixed reference beam structure, and a reference coding ruler or reference target is arranged on the independent rigid linear reference, and its coordinate system is unified with the workshop measurement reference network.

[0012] Preferably, the hinge pair is a ball joint or a universal joint, so that the normal contact head can adaptively adjust the swing angle according to the curved surface of the component, ensuring that the jacking force is transmitted along the local normal of the component.

[0013] Preferably, the servo drive unit is a servo electric cylinder or an electro-hydraulic servo cylinder; the displacement sensing unit is an absolute encoder integrated on the end of the servo motor shaft, or a linear displacement sensor fixed on the cylinder body.

[0014] Preferably, the series force measuring unit is a spoke-type force sensor or a column-type force sensor, used to collect the support reaction force value borne by the corresponding support mechanism in real time.

[0015] Preferably, the control cabinet is configured to perform high-frequency position and posture fine-tuning on the force-position integrated active support mechanism near the weld bead area based on the welding gun position information transmitted by the welding mechanism, and maintain the position and support reaction force locking of the force-position integrated active support mechanism far from the weld bead area, so as to realize zoned collaborative control; The control cabinet is also configured to independently control the lifting and lowering of each force-position integrated active support mechanism under the dual constraints of the linear deviation being within the preset tolerance range and the support reaction force being within the set range, and dynamically distribute the support reaction force at each point; the target stroke of each force-position integrated active support mechanism is calibrated according to the theoretical coordinates of the independent rigid linear reference, and a pre-camber amount higher than the theoretical linearity can be preset before welding to offset the weld shrinkage deformation during the welding process.

[0016] Preferably, the force-position integrated active support mechanism can be moved to directly below an independent rigid linear reference by supporting the X-axis walking component, and the servo drive unit lifts the normal contact head to fit against the bottom surface of the reference beam. Combined with the force value feedback from the series force measuring unit, the automatic calibration of the initial elevation is completed.

[0017] The beneficial effects of this invention are: This invention solves the inherent defects of traditional welding jigs, such as coupling between the reference and support, and the drift of accuracy due to load deformation, by adopting an architecture design that decouples the independent rigid linear reference with the support array. The independent reference does not bear the component load throughout the entire process, and its self-weight deflection is negligible. It has no accuracy drift over long-term use and can provide a unified absolute coordinate traceability for the entire support array. With the dual constraint control formed by the force measuring unit and displacement sensor connected in series in the main force transmission path, it can accurately identify and eliminate the defects of virtual support voids caused by the self-weight deflection of the plate. It ensures that the linear accuracy in the assembly stage is based on the real and effective load, significantly improves the assembly linear consistency of irregular steel components such as bending and torsion and variable cross-section, and greatly reduces the workload and production cost of post-weld flame straightening. This invention employs a point-by-point independent force-position integrated active support architecture, combined with weld position zoning and collaborative control logic. This allows for real-time compensation of linear fluctuations caused by weld shrinkage during welding. Combined with a bilateral symmetrical synchronous welding process, it effectively counteracts the angular deformation trend of unilateral welding, suppresses the accumulation of welding deformation, and ensures stable and controllable linear accuracy of the welded component. The support mechanism possesses longitudinal movement and automatic elevation calibration capabilities, enabling rapid adaptation to the support point adjustments of irregularly shaped components of different lengths and curvatures. It eliminates the need for repeated manual calibration using external instruments, resulting in high changeover efficiency and strong tooling adaptability. Furthermore, the entire process data can be automatically stored and traced, significantly improving process stability and replicability, and adapting to the needs of various production modes. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a first three-dimensional structural schematic diagram of a large irregular steel component assembly and welding device proposed in this invention; Figure 2 This is a second three-dimensional structural schematic diagram of a large irregular steel component assembly and welding device proposed in this invention; Figure 3 This is a front view structural schematic diagram of a large irregular steel component assembly and welding device proposed in this invention; Figure 4 This is a three-dimensional structural schematic diagram of an independent rigid linear reference in a large irregular steel component assembly and welding device proposed in this invention. Figure 5 This is a three-dimensional structural diagram of the force-position integrated active support mechanism in a large irregular steel component assembly and welding device proposed in this invention. Figure 6 This is a schematic diagram of the calibration and movement process of the force-position integrated active support mechanism in a large irregular steel component assembly and welding device proposed in this invention. Figure 7This invention relates to the adjustment process of an integrated force-position active support mechanism in a large irregular steel component assembly and welding device. Figure 8 for Figure 7 Enlarged schematic diagram of the structure at point A in the middle; Figure 9 This is a three-dimensional structural diagram of the side plate positioning mechanism in a large irregular steel component assembly and welding device proposed in this invention. Figure 10 This is a three-dimensional structural diagram of the plate thickness limiting clamping component in a large irregular steel component assembly welding device proposed in this invention.

[0019] In the diagram: 1. Feeding mechanism; 11. Three-axis moving assembly; 12. Feeding fixture assembly; 2. Welding mechanism; 21. Y-axis moving assembly; 22. Welding end X-axis displacement assembly; 23. Welding robot arm assembly; 3. Side plate positioning mechanism; 31. Side plate X-axis adjustment assembly; 32. Swing assembly; 33. Fixing frame; 34. Side plate clamping assembly; 35. Plate thickness limiting clamping assembly; 4. Independent rigid linear reference; 5. Force-position integrated active support mechanism; 51. Support X-axis walking assembly; 52. Servo drive unit; 53. Series force measuring unit; 54. Hinge pair; 55. Normal contact head; 56. Displacement sensing unit; 6. Control cabinet. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0021] refer to Figures 1-10 A large-scale irregular steel component assembly and welding device is used in the factory prefabrication and assembly welding process of large-scale irregular steel components. It addresses the problems of datum and support coupling, difficulty in eliminating self-weight deflection, and low welding deformation control accuracy in the assembly and welding process of irregular steel components such as bent-torsional box beams and variable cross-section beams. The device can actively construct the theoretical line shape of the component and complete the dynamic shape-preserving control of the entire welding process. The device includes an independent rigid linear datum 4, a support array arranged along the theoretical line shape of the component, a side plate positioning mechanism 3, a feeding mechanism 1, a welding mechanism 2, and a control cabinet 6.

[0022] The support array consists of several force-position integrated active support mechanisms 5. Each force-position integrated active support mechanism 5 can be independently moved along the length of the component and is arranged on a calibrated measuring base. It is responsible for bearing the plate to be welded and actively correcting the self-weight deflection deformation. An independent rigid linear reference 4 is fixedly arranged on the calibrated measuring base, independently of the support array, and does not have bearing contact with the component to be processed throughout the process. It is responsible for providing the absolute coordinate reference of the theoretical line of the component, and at the same time, it provides the force-position integrated active support mechanism 5 with a calibration starting elevation. The side plate positioning mechanism 3 is arranged to the side of the force-position integrated active support mechanism 5 and is used for positioning and clamping the web plate to be welded and adjusting the weld gap. The loading mechanism 1 is arranged to the side of the workstation and is responsible for transporting and loading the plate to be welded. The welding mechanism 2 is arranged to the support array and is responsible for the automated welding operation of the component weld. The control cabinet 6 is connected to the controller signals of the loading mechanism 1, the welding mechanism 2, the side plate positioning mechanism 3 and each force-position integrated active support mechanism 5 to realize the coordinated control and data acquisition of the entire device.

[0023] refer to Figure 3 , Figure 4 , Figure 5 and Figure 6 The independent rigid linear reference 4 adopts a ground-fixed reference beam structure. The main body is a high-rigidity box-type steel structure beam with extremely high bending stiffness and negligible self-weight deflection, meeting the requirements for long-term accuracy and stability. The bottom of the beam is fixed to the calibrated concrete measuring foundation by pre-embedded anchor bolts, extending along the length of the component and covering the length range of the largest processed component. The side of the independent rigid linear reference 4 is equipped with a reference coding ruler or reference target along the length direction. After installation, it is calibrated by connecting with the permanent measurement reference network in the workshop using a high-precision total station. The scale value of the reference coding ruler is converted into a unified absolute coordinate system in the workshop, so that any point on the beam corresponds to a unique absolute coordinate, which serves as the coordinate traceability reference for the entire device.

[0024] refer to Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 The force-position integrated active support mechanism 5 includes, from bottom to top, a base flange, a support X-axis walking component 51, a servo drive unit 52, a series force measuring unit 53, a hinged joint 54, and a normal contact head 55. The base flange is anchored to the measuring base and serves as the installation base for the entire support mechanism. The fixed end of the support X-axis walking component 51 is installed on the top surface of the base flange, and the moving end carries the servo drive unit 52 upwards, which can drive the upper overall structure to move independently along the length of the component, adapting to the adjustment of support points for irregularly shaped components with different widths and curvatures.

[0025] The cylinder of the servo drive unit 52 is fixedly installed on the upper part of the moving end of the X-axis walking component 51, and the output end is arranged vertically upward. In this embodiment, the servo drive unit 52 can be a servo electric cylinder or an electro-hydraulic servo cylinder, which has mechanical self-locking capability and can stably bear load at any stroke position. The servo drive unit 52 integrates a displacement sensing unit 56, which can be an absolute encoder integrated on the end of the servo motor shaft or a linear displacement sensor fixed on the side wall of the cylinder, to collect the extension and retraction stroke data of the output end of the servo drive unit 52 in real time.

[0026] The series force measuring unit 53 is connected in series between the output end of the servo drive unit 52 and the normal contact head 55. All the support reaction forces of the component are finally transmitted to the foundation flange through the normal contact head 55, the series force measuring unit 53, the servo drive unit 52, and the support X-direction walking component 51. The series force measuring unit 53 is in the only vertical force transmission main path, and there is no other load-bearing structure to form a lateral force bypass. Therefore, the measured load value is the real support reaction force at the support point. In this embodiment, the series force measuring unit 53 adopts a spoke-type force sensor or a column-type force sensor, which is strictly coaxially installed with the output end of the servo drive unit 52. It can collect the support reaction force value borne by the corresponding support point in real time, accurately identify the three working states of virtual support detachment (support reaction force close to zero), normal bearing, and local overload, and provide a real force basis for linear control.

[0027] The normal contact head 55 is connected to the upper flange of the series force measuring unit 53 through the hinge pair 54. The working surface of the normal contact head 55 is arranged in the local normal direction of the component. In this embodiment, the hinge pair 54 is a ball joint or a universal joint, which allows the contact head to deflect freely within a set angle range. When the support mechanism is lifted and the contact head contacts the curved or inclined surface of the lower surface of the component, the reaction force of the component will push the hinge pair 54 to deflect automatically until the top surface of the normal contact head 55 is completely in contact with the bottom surface of the component, automatically matching the local curved surface inclination angle of the component, ensuring that the jacking force is always transmitted along the local normal direction of the component, avoiding the lateral component force and additional torsional deformation generated by the traditional vertical lifting method, so that the correction force acts directly on the deformation direction.

[0028] The signal output terminals of the series force measuring unit 53 and displacement sensing unit 56 are both connected to the control cabinet 6. The control terminals of the X-axis walking component 51 and the servo drive unit 52 are controlled by the control cabinet 6. Each force-position integrated active support mechanism 5 is an independent control unit. The control cabinet 6 can send lifting and displacement commands to any support mechanism individually, and simultaneously collect displacement and support reaction force data at the corresponding points. This enables independent control of a single support mechanism and synchronous acquisition of status data, providing a hardware foundation for point-by-point dynamic linear control.

[0029] refer to Figure 1 , Figure 2 , Figure 3, Figure 9 and Figure 10 One side of the force-position integrated active support mechanism 5 is provided with a side plate positioning mechanism 3, which is used to cooperate with the bottom support array to complete the wing plate limiting and web plate assembly, ensuring the assembly accuracy of the component section and the uniformity of the weld gap; the side plate positioning mechanism 3 includes a side plate X-direction adjustment component 31, which is arranged along the length direction of the component, and a swing component 32 that can swing around the length direction of the component is installed on the upper part of its moving end; a fixed frame 33 is fixedly connected to the swing output end of the swing component 32, and a side plate clamping component 34 is installed on the surface of the component facing the fixed frame 33, and a plate thickness limiting clamping component 35 is provided on the upper part of the clamping side of the side plate clamping component 34.

[0030] The side plate clamping assembly 34 is positioned along the side edge of the lower flange plate, clamping and limiting the flange plate from the side to restrict lateral slippage during hoisting and welding. Together with the bottom support array, it maintains the planar position accuracy of the reference plate and prevents misalignment of the web plate assembly due to plate offset. The plate thickness limiting clamping assembly 35 is positioned along the thickness direction of the web plate and fixes the web plate by double-sided clamping to prevent tilting or planar offset after web plate assembly. The swing assembly 32 can drive the fixing frame 33 and the clamped web plate to deflect slightly around the length of the component to calibrate the verticality of the web plate assembly and ensure that the angle between the web plate and the flange plate meets the design requirements. The side plate X-axis adjustment assembly 31 can drive the entire side plate positioning mechanism 3 to translate along the length of the component, accurately adjusting the longitudinal alignment and bevel gap between the web plate and the bottom flange plate, ultimately ensuring that the form and position dimensions of the component section and the weld gap meet the welding process requirements.

[0031] refer to Figure 1 and Figure 2 The loading mechanism 1 includes a three-axis moving component 11 and a loading fixture component 12 installed on its moving terminal, which is used for handling, loading and positioning the plates to be welded; the control cabinet 6 is connected to the controller of the loading mechanism 1 to coordinate and control the operation rhythm.

[0032] refer to Figure 1 , Figure 2 and Figure 3 The welding mechanism 2 includes a Y-axis moving component 21, which is arranged along a direction perpendicular to the length of the component. At least two welding end X-axis shifting components 22 are installed at the moving end of the Y-axis moving component 21. Each welding end X-axis shifting component 22 is equipped with a welding robot arm component 23 at its moving end. The two welding robot arm components 23 are configured to move synchronously along the weld seam to achieve symmetrical synchronous welding of the component on both sides, offsetting the angular deformation trend caused by welding on one side and reducing the overall welding deformation. The control cabinet 6 is connected to the controller signal of the welding mechanism 2, which can obtain the spatial position information of the welding torch in real time and provide a workstation basis for the dynamic control of the support array.

[0033] In this implementation scheme, the control cabinet 6 has a built-in industrial controller and data storage module, which has the ability to coordinate and control in different zones: based on the welding gun position information transmitted by the welding mechanism 2, the support array is divided into a control zone near the weld bead and a stabilization zone far from the weld bead. High-frequency position and posture fine adjustment is performed on the force-position integrated active support mechanism 5 in the area near the weld bead, and the position and support reaction force are locked on the force-position integrated active support mechanism 5 in the area far from the weld bead. This zone control logic can not only compensate for the linear fluctuations in the weld bead area caused by weld shrinkage and cross-sectional stiffness changes in real time, but also avoid the accumulation of errors caused by frequent adjustments of the far-end support, thus taking into account both control accuracy and overall linear stability. Meanwhile, the control cabinet 6 independently controls the lifting and lowering of the integrated active support mechanism 5 at each force position, dynamically distributing the support reaction force at each point, with the linear deviation within the preset tolerance range and the support reaction force within the set range as dual constraints. The dual constraints are parallel AND logic relationships, and both conditions must be met simultaneously: the first is the linear deviation constraint, which uses the theoretical elevation calibrated by the independent rigid linear reference 4 as a benchmark to limit the allowable fluctuation range of the actual elevation of the support point. The data is fed back in real time by the displacement sensing unit 56, which is the core indicator to ensure the overall geometric accuracy of the component. The second is the support reaction force range constraint, which pre-sets the reasonable support reaction force range for each support point based on the component's self-weight, cross-sectional stiffness, and support spacing. The data is directly collected by the series force measuring unit 53, reflecting the actual contact bearing state between the support and the plate, and is used to avoid hidden defects such as virtual support voids or local overload.

[0034] The specific execution logic is divided into two stages according to the process. The first stage is the pre-welding billet lifting stage. Control cabinet 6 first drives all support mechanisms to lift synchronously according to the theoretical target elevation. After reaching the vicinity of the target elevation, the support reaction force value is read point by point. If the elevation of a certain point has entered the tolerance range, but the support reaction force is lower than the lower limit of the set interval, it means that the support at that point is not effectively attached to the plate and there is a loose connection. At this time, control cabinet 6 controls the support mechanism to continue to lift slightly. Under the premise that the displacement does not exceed the upper limit of the tolerance, the support reaction force is gradually increased until it enters the set interval. If the support reaction force at a certain point has reached the set value, but the elevation is still lower than the theoretical value, it means that the deflection of the local plate under its own weight is greater than expected. Then, the lifting continues until the elevation enters the tolerance range. At the same time, the support reaction force is monitored to ensure that it does not exceed the upper limit to avoid overload bending of the plate. After all points are adjusted, each support point simultaneously meets the requirements of elevation compliance and reasonable force, which not only ensures the geometric accuracy of the overall line shape, but also eliminates hidden virtual support defects and avoids abrupt changes in the line shape caused by the failure of virtual support points during the welding process.

[0035] The second stage is the dynamic control stage of the welding process. Due to heat input, the weld area shrinks and deforms, and the elevation and support reaction force of the corresponding support points will fluctuate in real time. Control cabinet 6 takes the weld position as the core and performs high-frequency inspection of the support structure in the adjacent area: when the elevation of a certain point deviates downward beyond the lower limit of the tolerance, a slight jacking is prioritized to compensate for the shrinkage, while monitoring the support reaction force to ensure it does not exceed the upper limit; when the support reaction force of a certain point rises abnormally beyond the upper limit of the interval, it indicates that the local welding shrinkage is squeezing the support, and a slight descent is performed to release the stress, while ensuring that the elevation does not exceed the lower limit of the tolerance. Through two-way closed-loop verification of displacement and force, the hidden defects of accurate elevation but unbalanced force under single displacement control are avoided, as well as the problem of uniform force but out-of-tolerance linearity under single force control, thus achieving precise and controllable welding deformation. By employing dual-constraint logic, this design addresses the pain point of traditional support jigs that only control the top surface elevation and cannot identify localized loose connections caused by the deflection of the plate's own weight. For irregularly shaped components with large spans and thin webs, the deflection due to their own weight is significant. Even if all support top surfaces are adjusted to the same elevation, gaps may still exist between the plate and some supports. During the welding process, as thermal deformation accumulates, the loose supports will gradually fail, ultimately causing inaccurate alignment. By introducing support reaction force constraints, the contact state and load-bearing effectiveness are directly judged by the force value, adding a mechanical verification step to the alignment accuracy and ensuring that the final geometric accuracy is based on the actual load-bearing capacity.

[0036] The target stroke of the integrated active support mechanism 5 is determined based on the theoretical coordinates of the independent rigid linear reference 4. Before welding, a pre-camber amount higher than the theoretical linearity can be preset to offset the weld shrinkage deformation during the welding process and ensure that the post-weld component line meets the design requirements.

[0037] The device has an automatic elevation calibration function. The force-position integrated active support mechanism 5 can be moved to the direct under the independent rigid linear reference 4 through the support X-direction walking component 51. The servo drive unit 52 lifts the normal contact head 55 to fit with the bottom surface of the reference beam. Combined with the force value feedback of the series force measuring unit 53, the automatic calibration of the starting elevation is completed. Accuracy recalibration can be achieved without manual assistance from external surveying instruments, ensuring the consistency of linear accuracy in long-term mass production.

[0038] Working principle: Before operation, the device's reference calibration and elevation adjustment are completed: Control cabinet 6 controls the integrated active support mechanism 5 of each force position to move sequentially to directly below the independent rigid linear reference 4 via the support X-axis walking component 51. Then, the servo drive unit 52 slowly lifts, driving the normal contact head 55 upwards towards the bottom surface of the reference beam. When the top surface of the normal contact head 55 is completely in contact with the reference surface at the bottom of the reference beam, the hinge pair 54 passively resets to the centered state, and at the same time, the series force measuring unit 53 detects that the pressure value continues to rise. When the pressure value reaches the set calibration threshold, it indicates that the contact head and the reference surface have been aligned. Completely compacted and without any loose connections, the control cabinet 6 records the current reading of the displacement sensing unit 56, and then controls the servo drive unit 52 to retract to the position where the force value of the series force measuring unit 53 returns to zero. At this point, the automatic calibration of the initial elevation of the support mechanism is completed. After all support mechanisms have completed calibration in sequence, the elevation reference of the entire array is traced back to the independent rigid linear reference 4, eliminating the installation errors, transmission gaps and wear drift of each support mechanism. After calibration, the servo drive unit 52 continues to retract and reset, and the support X-axis walking component 51 drives the upper structure to move to the preset support point, waiting for the material to be loaded and assembled.

[0039] During the billet assembly stage, the loading mechanism 1 hoists the lower flange plate above the support array. The control cabinet 6 controls each servo drive unit 52 to lift synchronously. After initially reaching the target elevation, the vacant support points are identified based on the feedback from the series force measuring unit 53. The corresponding support mechanism is then controlled to continue lifting slightly until the support reaction force at all points enters the design distribution range, precisely pushing the lower flange plate, which is deflected by its own weight, to the theoretical linear height. Subsequently, the side plate positioning mechanism 3 operates, adjusting the longitudinal position of the web plate through the side plate X-direction adjustment component 31, calibrating the verticality of the web plate through the swing component 32, and clamping and fixing the web plate by the side plate clamping component 34 and the plate thickness limiting clamping component 35, precisely adjusting the weld gap between the web plate and the lower flange plate. Finally, the upper flange plate is hoisted to complete the closure and positioning, forming a complete component section.

[0040] During the welding stage, welding mechanism 2 is activated, and two welding robot arm assemblies 23 move synchronously along the weld seam to perform symmetrical welding on both sides of the component. Control cabinet 6 receives welding gun position information from welding mechanism 2 in real time and divides the control area with the weld seam as the center: the support mechanism in the area near the weld seam performs high-frequency micro-lifting based on the real-time changes in support reaction force and displacement, lifting and supplementing force at the detachment point and lowering and unloading at the overload point to maintain the linear deviation within the tolerance range and the support reaction force is balanced; the support mechanism in the far area locks the position and support reaction force to maintain the overall linear stability of the component; during the welding process, the support height can be actively adjusted according to the preset pre-camber amount to offset the linear deformation caused by weld seam shrinkage.

[0041] After welding, the integrated active support mechanism 5 maintains the theoretical elevation position and locks in place. After cooling to room temperature, it descends synchronously and uniformly. The change of support reaction force is monitored throughout the process to achieve smooth unloading and avoid impact deformation. All force values, displacements and control parameters are automatically recorded and stored throughout the process, and the process data is traceable and reproducible.

[0042] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A large-scale irregular steel component assembly and welding device, comprising a support array and a control cabinet (6) arranged along the theoretical line of the component, characterized in that, It also includes an independent rigid linear reference (4), and the support array is a number of force-position integrated active support mechanisms (5), each of which can be independently moved along the width direction of the component and arranged on the calibrated measurement base; The independent rigid linear reference (4) is fixedly laid on the calibrated measurement base, independently of the support array, and does not have any bearing contact with the component to be processed throughout the process. It is used to provide the absolute coordinate reference of the theoretical linear shape of the component and to provide the force-position integrated active support mechanism (5) for calibrating the starting elevation. The force-position integrated active support mechanism (5) includes, from bottom to top, a base flange, a support X-axis walking assembly (51), a servo drive unit (52), a series force measuring unit (53), a hinge pair (54), and a normal contact head (55). The base flange is anchored to the measuring foundation. The fixed end of the support X-axis walking assembly (51) is installed on the base flange, and the moving end carries the servo drive unit (52) upward. The cylinder of the servo drive unit (52) is fixedly installed on the upper part of the moving end of the support X-axis walking assembly (51), and the output end is arranged vertically upward. The series force measuring unit (53) is connected in series between the output end of the servo drive unit (52) and the normal contact head (55), and is located in the main force transmission path of the component support reaction force. The normal contact head (55) is connected to the series force measuring unit (53) through the hinge pair (54), and the working surface of the normal contact head (55) is arranged in the local normal direction of the component. The servo drive unit (52) integrates a displacement sensing unit (56). The signal output terminals of the series force measuring unit (53) and displacement sensing unit (56) are both connected to the control cabinet (6), and the control terminals of the X-axis walking component (51) and servo drive unit (52) are controlled by the control cabinet (6).

2. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, It also includes a feeding mechanism (1), and the control cabinet (6) is connected to the controller signal of the feeding mechanism (1); the feeding mechanism (1) includes a three-axis moving assembly (11), and the moving terminal of the three-axis moving assembly (11) is equipped with a feeding fixture assembly (12) for clamping the plate to be welded.

3. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, It also includes a welding mechanism (2), and the control cabinet (6) is connected to the controller signal of the welding mechanism (2); the welding mechanism (2) includes a Y-axis moving component (21), and at least two welding end X-direction shifting components (22) are installed on the moving end of the Y-axis moving component (21), and each welding end X-direction shifting component (22) is equipped with a welding robot arm component (23) on its moving end; the two welding robot arm components (23) are configured to walk synchronously along the weld seam to achieve symmetrical synchronous welding of the component on both sides.

4. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The force-position integrated active support mechanism (5) is provided with a side plate positioning mechanism (3) on one side. The side plate positioning mechanism (3) includes a side plate X-direction adjustment component (31). The upper part of the moving end of the side plate X-direction adjustment component (31) is equipped with a swing component (32) that swings around the length direction of the component. The swing output end of the swing component (32) is fixedly connected to a fixed frame (33). The surface of the fixed frame (33) is equipped with a side plate clamping component (34). The clamping side of the side plate clamping component (34) is provided with a plate thickness limiting clamping component (35).

5. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The independent rigid linear reference (4) adopts a ground-fixed reference beam structure. The independent rigid linear reference (4) is equipped with a reference coding ruler or reference target, and its coordinate system is unified with the workshop measurement reference network.

6. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The hinge pair (54) is a ball joint or a universal joint, which allows the normal contact head (55) to adaptively adjust the swing angle according to the curved surface of the component, ensuring that the jacking force is transmitted along the local normal of the component.

7. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The servo drive unit (52) is a servo electric cylinder or an electro-hydraulic servo cylinder; the displacement sensing unit (56) is an absolute encoder integrated on the end of the servo motor shaft, or a linear displacement sensor fixed on the cylinder body.

8. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The series force measuring unit (53) is a spoke-type force sensor or a column-type force sensor, used to collect the support reaction force value borne by the corresponding support mechanism in real time.

9. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The control cabinet (6) is configured to perform high-frequency position fine adjustment on the force-position integrated active support mechanism (5) near the weld bead area based on the welding gun position information transmitted by the welding mechanism (2), and maintain the position and support reaction force lock of the force-position integrated active support mechanism (5) far away from the weld bead area, so as to realize zoned collaborative control. The control cabinet (6) is also configured to independently control the lifting and lowering of each force-position integrated active support mechanism (5) under the dual constraint conditions that the linear deviation is within the preset tolerance range and the support reaction force is within the set range, and dynamically distribute the support reaction force at each point; the target stroke of each force-position integrated active support mechanism (5) is determined according to the theoretical coordinate of the independent rigid linear reference (4), and a pre-camber amount higher than the theoretical linear can be preset before welding to offset the weld shrinkage deformation during the welding process.

10. The large-scale irregular steel component assembly and welding device according to claim 1, characterized in that, The force-position integrated active support mechanism (5) can be moved to the direct under the independent rigid linear reference (4) by supporting the X-direction walking component (51). The servo drive unit (52) lifts the normal contact head (55) to fit against the bottom surface of the reference beam. Combined with the force value feedback of the series force measuring unit (53), the automatic calibration of the starting elevation is completed.

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