A side beam assembly welding positioning system and positioning method

Abstract

The application relates to a side beam assembly welding positioning system and a positioning method, and relates to the technical field of steel structure welding positioning. The system comprises a reference positioning module, a supporting module, a lateral jacking module, a pressing module and a controller. Multiple workstations are arranged along the length direction of the side beam of each module, and detection units for sensing, adhering, bearing, jacking force and pressing force states are arranged. The controller executes a step-by-step linkage logic according to the detection signals, triggers the next action only after the previous state is confirmed to be completed, and continuously monitors the force value change during the welding process to automatically trigger pressure compensation. The application can realize state sensing and condition triggering linkage in the whole process of side beam assembly welding, effectively prevent the execution of subsequent operations before the previous steps are up to the standard, and automatically compensate for the positioning deviation caused by welding thermal deformation, thereby improving the positioning precision and welding quality.

Description

Technical Field

[0001] This application relates to the field of steel structure welding positioning technology, specifically to a side beam welding positioning system and positioning method. Background Technology

[0002] As a key foundational component in steel structure buildings, bridge engineering, and rail transit vehicle manufacturing, the quality of its assembly and welding directly determines the overall structure's load-bearing capacity, dimensional accuracy, and service life. In the manufacturing process of edge beams, precisely fixing the spatial position of the flange and web is a prerequisite for subsequent welding processes. Currently, modular specialized tooling is commonly used in this field for auxiliary operations. Its conventional technical route typically includes several main steps such as datum positioning, bottom support, lateral tightening, and upper clamping. Operators or automated equipment follow a predetermined process sequence to sequentially complete the lifting and placement of the workpiece, its alignment with the support, height adjustment, lateral force application, and final locking. This process relies on the coordinated cooperation of various functional modules, aiming to limit the workpiece's degrees of freedom through mechanical constraints, ensuring uniform weld gaps and that the component's geometry meets the design drawings. This is a standard operating mode in the intelligent manufacturing process of steel structures.

[0003] However, in the large-scale production of long-length, large-section edge beams, existing welding and positioning technologies still face some long-standing technical bottlenecks. Due to the lack of end-to-end state awareness and logical interlocking mechanisms, each step in the positioning process is often in a relatively independent or open-loop control state, making it difficult to confirm in real time whether the physical state of the preceding steps truly meets the expected standards before proceeding to the next operation. This results in accumulated errors not being promptly prevented. Furthermore, under the dynamic deformation environment caused by welding heat input, traditional static clamping methods struggle to maintain constant constraint forces, easily leading to positioning offsets due to force attenuation. Moreover, for the inherent initial wave deformation of long components, conventional unidirectional or random sequential force application strategies are insufficient to effectively eliminate residual stress, resulting in significant fluctuations in the straightness and perpendicularity of the final product, thus restricting the consistent manufacturing level of high-end steel structural components. Summary of the Invention

[0004] This application provides a side beam welding positioning system and method, which can solve the technical problems of entering subsequent operations before the physical state of the preceding steps is up to standard due to the lack of full-process state perception and logical interlocking mechanism, and the difficulty of maintaining constant constraint force in the traditional static clamping method under the dynamic deformation environment caused by welding heat input, resulting in positioning offset and fluctuation of finished product indicators.

[0005] To achieve the above objectives, this application provides the following technical solution: The first aspect of this application provides a side beam welding positioning system, comprising: The reference positioning module has multiple positioning stations arranged along the length of the side beam, and each positioning station is equipped with a first detection unit for sensing the fitting status. The support module, located on one side of the reference positioning module, has multiple support stations arranged along the length of the side beam. Each support station is equipped with a second detection unit for sensing the load-bearing status. The lateral clamping module is located on the side of the support module facing away from the reference positioning module. Multiple clamping stations are arranged along the length of the side beam, and each clamping station is equipped with a third detection unit for sensing the clamping force status. The clamping module has multiple clamping stations arranged along the length of the side beam, and each clamping station is equipped with a fourth detection unit for sensing the clamping force status. The controller, connected to each detection unit, is configured to execute a hierarchical linkage logic: the controller triggers support setting only after the first detection unit confirms the establishment of the reference; it triggers positioning confirmation only after the second detection unit confirms that all support surfaces are on the same horizontal plane; it triggers lateral tightening only after the second detection unit verifies positioning; it triggers pressing only after the first detection unit confirms fit and the third detection unit confirms that the pressing force reaches a preset threshold; and it generates a positioning completion signal after the fourth detection unit confirms that the pressing force reaches a preset threshold. This forms a hierarchical linkage positioning chain of reference establishment, support setting, positioning confirmation, lateral tightening, and pressing fixation. There is a condition triggering mechanism between adjacent levels, executed by the controller and based on the sensing signals of the detection units.

[0006] In an optional embodiment, the controller is further configured to continuously receive sensing signals from the third and fourth detection units during the welding process. When the clamping force value sensed by the third detection unit is lower than the preset clamping force threshold, the corresponding clamping station is automatically triggered to replenish pressure. When the clamping force value sensed by the fourth detection unit is lower than the preset clamping force threshold, the corresponding clamping station is automatically triggered to replenish pressure. During the replenishment process, the controller continuously monitors the signal from the first detection unit. If the first detection unit senses that the bonding state is damaged, it triggers an alarm and stops welding.

[0007] In one optional embodiment, when the controller performs lateral clamping, it drives each clamping station in a sequential order from the middle position of the side beam to both ends, with the clamping station at the middle position reaching the preset clamping force threshold before the clamping stations at both ends; when the controller performs pressing, it drives each pressing station in a sequential order from the middle position of the side beam to both ends, and the pressing sequence is consistent with the clamping sequence.

[0008] In one optional embodiment, the first detection unit includes a plurality of first sensing elements distributed along the length of the side beam. Each first sensing element is used to detect the fitting gap between the side of the side beam and the positioning reference surface at the corresponding positioning station. When the fitting gap detected by all the first sensing elements is less than a preset gap threshold, a positioning signal is output.

[0009] In one optional embodiment, the second detection unit includes a plurality of second sensing elements distributed along the length of the side beam. Each second sensing element is used to detect the load-bearing status and load at the corresponding support position. When the load detected by all the second sensing elements is greater than a preset load threshold and the load distribution deviation is less than a preset deviation threshold, a side beam positioning confirmation signal is output.

[0010] In one optional embodiment, the third detection unit includes a plurality of third sensing elements distributed along the length of the side beam. Each third sensing element is used to detect the clamping force value at the corresponding clamping station. The controller adjusts the clamping force of each clamping station according to the feedback signal of each third sensing element so that the clamping force of each clamping station is consistent and reaches the preset clamping force threshold.

[0011] In one optional embodiment, the fourth detection unit includes a plurality of fourth sensing elements distributed along the length of the side beam. Each fourth sensing element is used to detect the clamping force value at the corresponding clamping station. The controller adjusts the clamping force of each clamping station according to the feedback signal of each fourth sensing element so that the clamping force of each clamping station is consistent and reaches the preset clamping force threshold.

[0012] In an optional embodiment, the controller is further configured to: when triggering the pressure replenishment operation, simultaneously compare the top clamping force sensed by the third detection unit and the pressing force sensed by the fourth detection unit; if either force value still cannot reach the corresponding preset threshold after pressure replenishment, then determine that the side beam has irreversible deformation and trigger a shutdown alarm.

[0013] The second aspect of this application provides a method for positioning a welded edge beam, employing the edge beam welding positioning system described above, comprising the following steps: S1, datum establishment: The datum positioning module establishes a global positioning datum. The first detection unit senses the state of the positioning datum surface at each positioning station. When the first detection unit confirms that the positioning datum surfaces are coplanar and the position deviation is less than a preset deviation threshold, a datum establishment completion signal is generated; S2, support setting: After receiving the datum establishment completion signal, the controller calculates the target support height at each support station based on the edge beam cross-sectional parameters and drives the adjustment. After the second detection unit confirms that each support surface is on the same horizontal plane, a support datum establishment signal is generated; S3, positioning confirmation: The edge beam is placed on each support station. The second detection unit senses changes in the load-bearing state and generates an edge beam positioning confirmation signal after verifying that the edge beam is in the correct position; S4, lateral tightening: After receiving the edge beam positioning confirmation signal, the controller... S5. Tightening and Fixing: After receiving the lateral positioning completion signal, the controller drives each tightening station to tighten the side beam from above. The fourth detection unit senses the tightening force value in real time. The fourth detection unit senses the tightening force value in real time. The fourth detection unit senses the tightening force value in real time. The fourth detection unit senses the tightening force of each tightening station to reach the preset threshold and generates a positioning completion signal. S6. Welding Monitoring and Pressure Replenishment: During the welding process, the third and fourth detection units continuously sense the tightening force and pressure retention status. When the force value sensed by any detection unit is lower than the corresponding preset threshold, the controller automatically triggers pressure replenishment at the corresponding station. During the pressure replenishment process, the first detection unit synchronously monitors the bonding status. If the bonding status is damaged, an alarm is triggered and welding is stopped.

[0014] In one optional embodiment, in step S4, the lateral tightening force is applied in an order that increases sequentially from the middle position of the side beam to both ends along the length direction. The tightening station at the middle position reaches the preset tightening force threshold first, and the tightening stations at both ends reach the preset tightening force threshold later. In step S5, the clamping force is applied sequentially from the middle position of the side beam to both ends along the length direction, and the clamping sequence is consistent with the tightening sequence in step S4.

[0015] This application provides a positioning system and method for welding edge beams. The system comprises a five-module system: a reference positioning module, a support module, a lateral tightening module, a clamping module, and a controller. Each module is equipped with first to fourth detection units to achieve comprehensive real-time sensing of the fit, load-bearing, tightening, and clamping force states. Based on this sensing network, the controller strictly executes a hierarchical linkage logic of reference establishment, support setting, positioning confirmation, lateral tightening, and clamping fixation. The signal confirming completion by the previous detection unit serves as the sole trigger condition for the next action, ensuring that the physical state of each step meets the standards is a necessary prerequisite for the process. This mechanism prevents the forced entry into subsequent processes if previous steps are incomplete or substandard. Furthermore, the system introduces a dynamic monitoring and automatic pressure compensation mechanism during welding. By continuously comparing real-time force values ​​with preset thresholds, it automatically triggers compensation actions when force attenuation due to thermal deformation is detected, and simultaneously verifies the integrity of the reference fit, thereby achieving active suppression and closed-loop control of welding deformation. This effectively solves the technical problems caused by the lack of full-process state awareness and logical interlocking mechanism, which leads to the subsequent operation proceeding before the physical state of the preceding steps meets the standards, and the difficulty of maintaining constant constraint force in the traditional static clamping method under the dynamic deformation environment caused by welding heat input, resulting in positioning offset and fluctuation of finished product indicators. Therefore, it avoids positioning failure and product quality inconsistency caused by missing steps, cumulative error transmission and lag in thermal deformation compensation, and significantly improves the positioning accuracy, process stability and geometric consistency of the final product in the welding of side beams. Attached Figure Description

[0016] Figure 1 This application provides a schematic diagram of a side beam welding positioning system. Figure 2 A flowchart for the force-value monitoring-triggered pressure replenishment and bonding failure alarm in the edge beam welding positioning system provided in this application; Figure 3 A flowchart illustrating the tightening and pressing operations performed sequentially from the middle to both ends in the edge beam welding positioning system provided in this application; Figure 4 A flowchart of a side beam welding positioning method provided in this application; Figure 5 The flowchart illustrates the application of tightening and pressing forces sequentially from the middle to both ends in the side beam welding positioning method provided in this application. Detailed Implementation

[0017] The present application will now be described in further detail with reference to embodiments. It is to be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the scope of the application.

[0018] Example 1: like Figure 1 As shown, this embodiment provides a side beam welding positioning system, which includes: a reference positioning module, a support module, a lateral clamping module, a pressing module, and a controller. The reference positioning module has multiple positioning stations arranged along the length of the side beam, and each positioning station is equipped with a first detection unit for sensing the fit status.

[0019] Specifically, the reference positioning module, as the core of the geometric reference of the entire welding positioning system, primarily functions to provide a defined lateral positioning reference surface for the edge beam to be welded. Multiple positioning stations are distributed along the length of the edge beam to accommodate the multi-point support requirements of long-sized edge beams and prevent flexural deformation caused by large spans from affecting positioning accuracy. A first detection unit is installed at each positioning station to sense the contact state between the edge beam and the positioning reference surface in real time. This contact state can be sensed using contact sensors, such as contact switches or pressure sensors arranged on the positioning surface; when the edge beam effectively abuts against the positioning surface, the sensor emits a signal. Alternatively, non-contact displacement sensors or distance sensors can be used to determine whether the contact tolerance requirement is met by detecting changes in the distance between the edge beam surface and the positioning reference surface. For example, if the contact threshold is set to... When the detection distance The system is deemed to be in effective contact upon arrival. The first detection unit enables the controller to obtain real-time data on whether the side beam has accurately fallen into the reference position, providing the necessary prerequisite for triggering subsequent actions.

[0020] A support module, located on one side of the reference positioning module, has multiple support stations arranged along the length of the side beam. Each support station is equipped with a second detection unit for sensing the load-bearing status. In this embodiment, the support module undertakes the function of gravity support for the side beam. Its arrangement on one side of the reference positioning module forms a stable force-bearing configuration of lateral positioning + bottom support. The second detection unit at each support station is used to sense the load-bearing status, i.e., to detect whether the support station has effectively borne the gravity load of the side beam. The second detection unit can be implemented as a pressure sensor, a weighing sensor, or a hydraulic / pneumatic branch pressure monitoring unit with pressure sensing function. For example, when using a pressure sensor, if the detected support force... satisfy If the load-bearing capacity is found to be normal, it indicates that the edge beam has been stably placed on the support module without any suspension or abnormal point contact. Through the second detection unit arranged at multiple points, the system can also identify whether the edge beam has localized warping or twisting. If the load-bearing capacity at a certain point is abnormally low or high, it indicates that the edge beam has initial deformation, thus providing data support for subsequent levelness verification.

[0021] The lateral clamping module, located on the side of the support module opposite to the reference positioning module, has multiple clamping stations arranged along the length of the side beam. Each clamping station is equipped with a third detection unit for sensing the clamping force. In this structure, the lateral clamping module and the reference positioning module are arranged opposite each other, together forming a clamping mechanism for the width direction of the side beam. The lateral clamping module, located on the side of the support module opposite to the reference positioning module, applies clamping force from the other side of the side beam, pushing the side beam towards the reference positioning module to ensure that the side beam is reliably clamped in the width direction. The third detection unit at each clamping station is used to sense the clamping force, and its core function is to monitor whether the clamping action has reached a preset clamping force threshold. The third detection unit is usually connected in series or parallel in the force transmission path of the clamping drive mechanism (such as a hydraulic cylinder, pneumatic cylinder, or electric push rod), and uses a force sensor or pressure sensor to collect force signals in real time. For example, clamping force... The monitoring needs to meet ,in The minimum clamping force threshold is set according to the welding process requirements. This threshold is used to ensure that the side beam will not undergo lateral displacement due to thermal shrinkage during the welding process. Through feedback from the third detection unit, the system can achieve closed-loop control of the clamping force, preventing positioning loosening due to insufficient clamping force or elastic deformation of the side beam due to excessive clamping force.

[0022] The clamping module has multiple clamping stations arranged along the length of the edge beam, each equipped with a fourth detection unit to sense the clamping force. The function of the clamping module is to apply clamping force to the edge beam vertically, fixing it to the support module and preventing the edge beam from arching or warping due to the heat input of the welding arc during welding. The arrangement of multiple clamping stations ensures a uniform distribution of clamping force. The fourth detection unit at each clamping station senses the clamping force, and its principle is similar to that of the third detection unit, aiming to monitor the magnitude of the vertical clamping force. The fourth detection unit can be integrated into the piston rod end of the clamping cylinder or the contact surface between the clamping head and the edge beam. In engineering applications, the setting of the clamping force usually needs to consider the cross-sectional stiffness of the edge beam and the welding heat input. The typical relation can be expressed as: ,in Stiffness coefficients are related to material properties and cross-sectional shape. This represents the estimated equivalent temperature difference change. Through the fourth detection unit, the controller can precisely adjust the clamping force at each clamping point, ensuring effective suppression of deformation while avoiding excessive clamping force that could lead to indentations or internal stress damage.

[0023] The controller, connected to each detection unit, is configured to execute tiered linkage logic. Specifically, as the core of the system, the controller is implemented using a programmable logic controller (PLC), industrial computer (IPC), or distributed control system (DCS). It establishes signal connections with the first, second, third, and fourth detection units via wired or wireless communication, acquiring real-time status data from each station. Tiered linkage logic refers to a strictly pre-set sequential control program within the controller. This program divides the entire positioning process into several consecutive stages, with the completion of the previous stage being a necessary condition for the start of the next. This logic design completely abandons the traditional open-loop control mode based on time relays, instead adopting a conditional triggering mode based on actual physical state feedback, thus ensuring the reliability of each operation step.

[0024] The controller triggers support setting only after the first detection unit confirms the establishment of the reference, and triggers positioning confirmation only after the second detection unit confirms that all support surfaces are on the same horizontal plane. In this embodiment, the establishment of the reference can mean that the first detection unit at all positioning stations reports that the side beam is effectively in contact with the reference surface. At this time, the controller determines that the lateral reference has been formed and then triggers the support setting action, such as controlling the lifting mechanism of the support module to rise to contact and lift the side beam. Subsequently, the system enters the level verification stage. The controller determines whether each support surface is on the same horizontal plane based on the data (such as height value or pressure distribution) fed back by the second detection unit at each support station. This judgment process can be based on a flatness error algorithm, for example, selecting three reference points to construct a reference plane and calculating the distance deviation of the remaining points from the plane. If all deviations satisfy ( (Assuming a preset tolerance), then confirm that all support surfaces are coplanar and level. Only after the levelness is confirmed to be correct will the controller trigger a positioning confirmation signal, indicating that the side beam is in the correct spatial posture and can proceed to the next step.

[0025] Lateral tightening is triggered only after the second detection unit verifies the positioning; pressing is triggered only after the first detection unit confirms fit and the third detection unit confirms the tightening force reaches a preset threshold; and a positioning completion signal is generated after the fourth detection unit confirms the pressing force reaches a preset threshold. This forms a hierarchical linkage positioning chain of baseline establishment, support setting, positioning confirmation, lateral tightening, and pressing fixation. A conditional triggering mechanism based on the detection unit's sensed signals, executed by the controller, exists between adjacent stages. Further, after positioning confirmation, the controller initiates the lateral tightening program, controlling the lateral tightening module's operation. At this time, the controller continuously monitors the feedback from the third detection unit; once the tightening force is detected... Reaching the preset threshold This indicates that the lateral clamping is in place. The clamping phase then begins, where the controller employs a dual confirmation mechanism: the first detection unit confirms that the side beam remains in contact with the reference surface (to prevent displacement during clamping), and the third detection unit confirms that the clamping force remains within a preset threshold range. Only when both conditions are met will the controller trigger the clamping module. Finally, the controller determines whether the clamping force meets the standard based on feedback from the fourth detection unit. If the preset requirements are met, a positioning completion signal is generated, and the system enters a locked or held state. This process forms a tightly linked, hierarchical positioning chain. The actions between adjacent levels are not simply sequential in time, but rather governed by a strict logical AND relationship, meaning that both temporal sequence and state conditions must be met simultaneously. This conditional triggering mechanism, based on signals sensed by detection units, ensures that the execution of any level of action is grounded in the actual physical condition of all preceding steps, thus logically eliminating the risk of positioning failure due to misoperation or external interference.

[0026] The core innovation of this application lies in the construction of a side beam welding positioning system based on multi-source state perception and a step-by-step condition triggering mechanism. This system integrates dedicated state detection units into four functional modules: benchmark positioning, support, lateral tightening, and clamping. This enables real-time quantitative monitoring of key physical quantities (such as fit, load-bearing capacity, tightening force, and clamping force) throughout the positioning process. Based on these real-time sensing signals, the controller strictly executes a five-level linkage logic: benchmark establishment, support setting, positioning confirmation, lateral tightening, and clamping fixation. This upgrades traditional open-loop sequential control to closed-loop state feedback control, ensuring that each operation is triggered only after the physical state of the preceding step has been confirmed as true. This establishes a data-driven, self-verifying automated positioning chain.

[0027] The working process and principle of this application are as follows: First, the side beam to be welded is hoisted above the system, and the controller puts each module into an initial standby state. During the descent of the side beam, the first detection unit of the reference positioning module monitors the contact between the side wall of the side beam and the positioning surface in real time. When all first detection units confirm that the contact signal is valid, the controller determines that the reference is established and then outputs a support setting command to control the support module to rise and lift the side beam. After the support module is in place, the second detection unit of each support station collects support force or height data. The controller uses an algorithm to fit the spatial position of each support point to verify whether they are on the same horizontal plane. If the levelness meets the tolerance requirements, the controller sends a positioning confirmation signal and starts the lateral clamping module. During the operation of the lateral clamping module, the third detection unit provides real-time feedback on the clamping force value. When the clamping force reaches the preset threshold and the first detection unit reports that the side beam is still in contact with the reference surface, the controller determines that the lateral fixation is reliable and unlocks the clamping module. The clamping module descends to clamp the side beam, and the fourth detection unit monitors the change in clamping force. Once the clamping force reaches the preset threshold, the controller generates a positioning completion signal, locks each actuator, and waits for the welding operation to begin.

[0028] Through the above technical solution, this application achieves the following beneficial effects: Because specific detection units are introduced for state perception at each positioning stage, and a strict hierarchical linkage logic is executed through a controller, the problem of performing subsequent clamping operations when preconditions such as inaccurate edge beam fit, horizontal support, or insufficient clamping force are not met is completely eliminated. This effectively solves the positioning failure and welding deformation risks caused by the lack of state monitoring in existing technologies. Simultaneously, the conditional triggering mechanism based on sensing signals between adjacent stages ensures that the execution of each operation is based on real physical state feedback, significantly improving the accuracy, consistency, and reliability of edge beam welding positioning. Furthermore, the combination of this modular design and full-process digital monitoring gives the system good maintainability and process adaptability, allowing for flexible adjustment of trigger thresholds at each stage according to the welding requirements of edge beams of different specifications, greatly improving the intelligence level of automated welding production lines.

[0029] Example 2: like Figure 2As shown, this application embodiment provides a control logic based on force value monitoring triggering pressure compensation and adhesion failure alarm. The controller is also configured to continuously receive sensing signals from the third and fourth detection units during the welding process. When the clamping force value sensed by the third detection unit is lower than the preset clamping force threshold, the corresponding clamping station is automatically triggered for pressure compensation. When the clamping force value sensed by the fourth detection unit is lower than the preset clamping force threshold, the corresponding clamping station is automatically triggered for pressure compensation. During the welding process of the edge beam, heat input causes thermal expansion and phase change of the workpiece material, which in turn causes changes in the geometric dimensions of the workpiece. This thermal deformation often releases or cancels the original clamping and clamping forces. This embodiment uses the controller to collect the force value signals from the third and fourth detection units in real time, transforming the traditional static clamping into a dynamic monitoring and compensation mechanism. The preset clamping force threshold and the preset clamping force threshold are the critical force values ​​required to ensure that the edge beam does not undergo relative displacement during the welding process. Their specific values ​​can be calculated or calibrated according to the cross-sectional dimensions, plate thickness, material, and welding heat input of the edge beam. For example, the preset clamping force threshold can be expressed as: ,in, For the required preset clamping force threshold, This is a safety factor (typically ranging from 1.2 to 1.5). The yield strength of the edge beam material at the welding temperature. This refers to the effective contact area between the clamping station and the side beam. When the controller detects that the real-time force value is lower than this threshold, it immediately sends a pressure compensation command to the corresponding actuator, driving the clamping or pressing mechanism to operate until the force value returns to the preset range, thereby ensuring that the workpiece is always in a state of effective constraint and effectively suppressing welding deformation.

[0030] During the pressure replenishment process, the controller continuously monitors the signal from the first detection unit. If the first detection unit detects that the bonding state has been disrupted, it triggers an alarm and stops welding. Applying additional force to the side beam during the pressure replenishment action may disturb the established positioning reference, especially when the side beam already has significant residual welding stress. Unilateral or localized pressure replenishment may cause slight rotation or warping of the workpiece, thereby disrupting the bonding state between the side beam and the reference positioning module. The first detection unit monitors the bonding state in real time; its detection signal can be a displacement signal or a pressure distribution signal. While executing the pressure replenishment logic, the controller runs the reference verification logic in parallel. Once it detects that the bonding gap exceeds the allowable range (e.g., a bonding gap greater than 0.1 mm), it determines that the bonding state has been disrupted, indicating that the pressure replenishment action or welding deformation has jeopardized the integrity of the positioning reference. At this time, the controller immediately triggers an alarm and stops welding to prevent irreversible dimensional deviations or structural defects from occurring while welding is in a positional failure state. This dual safety mechanism of pressure compensation and verification not only realizes automatic compensation of clamping force during welding, but also ensures the safety of the pressure compensation action itself through real-time monitoring of the reference state, forming a closed-loop control of monitoring, judgment, compensation, and verification, which significantly improves the stability of the welding process and the yield of finished products.

[0031] Example 3: like Figure 3 As shown, this application embodiment provides a control logic for a side beam welding positioning system, which involves an execution sequence strategy for lateral tightening and pressing. Specifically, when performing lateral tightening, the controller drives each tightening station in an order that increases sequentially from the middle position along the length of the side beam towards both ends. The tightening station at the middle position reaches the preset tightening force threshold before the tightening stations at both ends.

[0032] In this embodiment, the edge beam is typically a long-length component (such as an H-beam or box girder), inevitably exhibiting inherent initial bending or wavy deformation along its length. If a traditional tightening sequence from one end to the other is used, the deformation of the untightened portion is often pushed and accumulated at the end by the tightened portion, resulting in significant residual displacement at the end and causing overall straightness deviations. To address this issue, this embodiment employs a tightening strategy prioritizing the middle and gradually expanding. Specifically, the controller first drives the tightening station located at the center or middle region along the length of the edge beam, causing it to contact the edge beam first and reach a preset tightening force threshold. At this point, the middle position is fixed as a rigid anchor point, dividing the edge beam into two free segments along its length. Subsequently, the controller sends drive commands to the tightening stations on both sides of the middle position according to predetermined logic, causing the tightening action to expand symmetrically or incrementally from the middle towards both ends. This sequence allows the deformation on both sides of the edge beam to be naturally released towards the still-free ends when it is subjected to lateral constraints, rather than being forcibly squeezed to a fixed end. This effectively eliminates cumulative deformation errors and ensures the straightness accuracy of the edge beam along its entire length. It should be understood that the aforementioned intermediate position can refer to a workstation at the geometric center of the edge beam, or it can refer to a group of workstations arranged symmetrically around the center, which can be set according to the length and stiffness distribution of the edge beam.

[0033] During the clamping process, the controller drives each clamping station in a sequential order, applying pressure from the middle of the side beam towards both ends, with the clamping sequence matching the top-tightening sequence. After the lateral top-tightening process is completed, the side beam is reliably positioned horizontally. At this point, the clamping process begins, with the controller controlling the clamping module to apply clamping force to the side beam from above, fixing it to the support module. This embodiment further defines the spatial sequence of the clamping actions, also following the rule from the middle to both ends. This means that the clamping station located in the middle position will start first and reach the preset clamping force threshold, followed by the clamping stations on both sides acting sequentially. More importantly, this embodiment requires the clamping sequence to be consistent with the top-tightening sequence. Since the lateral top-tightening has established the lateral geometric constraint relationship of the side beam according to a specific sequence, if a completely different sequence is used during the clamping process (e.g., clamping from both ends to the middle), the frictional force and vertically downward deformation generated by the clamping force may disturb the established lateral positioning state, causing slight torsion or displacement of the side beam and compromising the original positioning accuracy. By maintaining consistency between the clamping and jacking sequences, it is ensured that during the clamping process, the lateral supports and jacking constraints beneath each area being clamped are fully locked and stable. This spatiotemporal coordination ensures that the lateral positioning reference remains stable throughout the clamping process, preventing flange warping or web twisting caused by improper clamping sequence, and further improving the overall quality and stability of the welding positioning.

[0034] Through the above technical solution, this application achieves optimized positioning control for long edge beams. The controller, by executing a sequential control strategy from the middle to both ends, utilizes the constraint point established first in the middle as the boundary point for deformation release, effectively solving the problems of deformation accumulation and residual stress concentration that easily occur during multi-point clamping and pressing of long components. Simultaneously, the strict consistency between the pressing sequence and the clamping sequence ensures the integrity and stability of the lateral positioning state during the vertical clamping process, avoiding positioning accuracy loss due to sequence conflicts between processes. This collaborative sequential control strategy significantly reduces the amount of post-weld correction work and improves the yield and dimensional consistency of edge beam welding.

[0035] Example 4: In another embodiment, this application also provides a first detection unit. The first detection unit includes a plurality of first sensing elements distributed along the length of the side beam. Each first sensing element is used to detect the fitting gap between the side surface of the side beam and the positioning reference surface at the corresponding positioning station. When the fitting gap detected by all the first sensing elements is less than a preset gap threshold, a positioning signal is output.

[0036] The first sensing element is the core component for quantifying the baseline establishment state. Its distribution along the length of the edge beam allows for multi-point coverage detection of the side-mounted fit along the entire beam length, avoiding the omission of local warping or deformation due to single-point detection. For example, the first sensing element can be a contact displacement sensor, such as an inductive displacement sensor or a linear displacement sensor, whose probe directly abuts against the side of the edge beam or the positioning reference surface to measure the gap; or it can be a non-contact distance detection element, such as a laser displacement sensor or an ultrasonic distance sensor, which emits a probe wave towards the side of the edge beam and receives the reflected wave to calculate the distance. Regardless of the form, the first sensing element is used to convert the ambiguous state of physical fit into a precise fit gap value for the controller to make logical judgments. In practical applications, the number and distribution density of the first sensing elements can be set according to the length specifications and accuracy requirements of the edge beam. For example, they can be strategically placed at both ends and key stress points in the middle of the edge beam to balance detection accuracy and cost control. Each first sensing element corresponds to a positioning station, independently detecting the gap data at that location, ensuring the decoupling and accuracy of the detection results.

[0037] The preset gap threshold is a quantitative standard for determining whether the benchmark establishment is qualified. Its specific value can be set according to the manufacturing tolerance of the side beam, the welding accuracy requirements, and the mechanical accuracy of the positioning system. For example, it can be 0.05mm, 0.1mm, or other allowable error values. The judgment logic adopts a pass-through mechanism, that is, only when the fitting gap values ​​detected by all distributed first sensing elements simultaneously meet the condition of being less than the preset gap threshold will the first detection unit output a high-level or specifically coded positioning signal to the controller; if the gap value detected by any first sensing element exceeds the threshold, it is considered that the benchmark establishment is not completed, and no positioning signal is output. This multi-point collaborative judgment mechanism can effectively eliminate false fitting signals caused by local burrs, oxide scale, or installation errors, ensuring that subsequent support setting steps are triggered only after the side beam achieves tight and uniform fitting with the positioning benchmark surface along its entire length. Through the above technical solution, this application realizes the transformation of subjective fitting state judgment into objective, data-based threshold comparison, providing a highly reliable starting trigger signal for the step-by-step linkage positioning chain, and effectively solving the problem of subsequent positioning cumulative error caused by inaccurate benchmark judgment.

[0038] Example 5: In another optional embodiment, this application also provides a second detection unit. The second detection unit includes multiple second sensing elements distributed along the length of the edge beam. Each second sensing element is used to detect the load-bearing status and load capacity at its corresponding support station. The second sensing element is the core component for the support module to achieve status sensing. Its specific form can be a pressure sensor, a load cell, or a force-measuring pin, etc., installed on the top of the support column or on the force transmission path of the support station, used to collect the physical pressure value generated after the edge beam is placed at the support station in real time. The load-bearing status refers to whether the support station is under stress, used to determine whether the edge beam has been effectively placed on the support point; the load capacity refers to the specific force value, reflecting the distribution of the edge beam's weight at each support station. Through multiple second sensing elements distributed along the length of the edge beam, the system can acquire load distribution data of the edge beam over its entire length, thereby providing a basis for judging the placement quality of the edge beam.

[0039] When the load detected by all second sensing elements is greater than the preset load threshold and the load distribution deviation is less than the preset deviation threshold, a side beam positioning confirmation signal is output. This judgment logic constitutes the positioning confirmation mechanism of the support module, which includes two parallel necessary conditions. The preset load threshold is the minimum force value standard used to determine the effective load of a single support station. It must be set to be greater than the zero-point drift value under no-load and less than the theoretical pressure distribution value of the side beam under single-point support. For example, it can be 5% to 10% of the total weight of the side beam. This is used to filter out invalid support points with false contact or no contact, preventing the side beam from being suspended or falsely supported. The load distribution deviation is used to measure the uniformity of the load among the support stations, reflecting the horizontal state of the side beam in the length direction or whether there is a stress concentration phenomenon caused by three-point support. The load distribution deviation can be determined by calculating the variance or range of the detection values ​​of each second sensing element, for example, it can be expressed as ,in For the first The load detected by the second sensing element The average load is detected for all second sensing elements. This represents the total number of the second sensing elements. The calculated distribution deviation... When the deviation is less than the preset threshold, it indicates that all support positions are on the same horizontal plane and the side beam is stably placed. The controller only outputs a side beam positioning confirmation signal when both of the above conditions are met simultaneously, thereby ensuring that subsequent lateral tightening and pressing operations are based on the side beam being real, horizontal, and under balanced stress, effectively avoiding side beam tilting or welding deformation caused by inconsistent support surface height.

[0040] Through the above technical solution, this application achieves accurate positioning determination of the edge beam based on dual sensing conditions. By coupling the determination of preset load-bearing threshold and load distribution deviation, it not only ensures that the edge beam achieves effective load-bearing at each support position, eliminating the risk of false contact, but also ensures the levelness of the support module itself and the straightness of the edge beam placement through load distribution uniformity verification. This positioning confirmation mechanism based on quantitative data replaces traditional manual visual inspection, fundamentally eliminating the problem of edge beam skew caused by single-point support failure or uneven support height, providing a reliable geometric benchmark and mechanical basis for subsequent lateral tightening processes, and significantly improving the positioning accuracy and stability of the edge beam welding positioning system.

[0041] Example 6: In an optional embodiment, this application also provides a third detection unit. The third detection unit includes multiple third sensing elements distributed along the length of the edge beam. Each third sensing element is used to detect the clamping force value at the corresponding clamping station. The controller adjusts the clamping force at each clamping station based on the feedback signal from each third sensing element, ensuring that the clamping force at each clamping station remains consistent and reaches a preset clamping force threshold.

[0042] The third sensing element is a key component for accurately sensing the lateral clamping force. It can be a pressure sensor, torque sensor, or strain gauge—any element capable of converting physical force values ​​into electrical signals. Multiple third sensing elements are distributed along the length of the side beam, enabling independent monitoring of the stress state at different cross-sectional locations. This allows for the detection of uneven stress caused by deviations in the beam's straightness or local deformation. Each third sensing element collects the clamping force value at its corresponding clamping station in real time and feeds this analog or digital signal back to the controller, providing a data foundation for subsequent closed-loop control.

[0043] The controller receives feedback signals from all third-party sensing elements and issues adjustment commands to the actuators (such as hydraulic valves and electric actuators) at each clamping station through a preset control algorithm. The adjustment process has two core objectives: first, force consistency, ensuring that the clamping force applied to each clamping station along the length of the side beam is essentially the same, avoiding additional deformation of the side beam due to localized over-tightening or positioning failure due to localized over-loosening; second, reaching the preset clamping force threshold, ensuring that the final clamping force value meets process requirements and provides sufficient lateral constraint force to resist thermal deformation during welding. In actual adjustment, the controller can adopt a phased control strategy, such as first adjusting each clamping force value to be consistent and then synchronously increasing it to the preset clamping force threshold, or a synchronous approximation strategy, so that the clamping force at each station simultaneously approaches the preset clamping force threshold while maintaining a dynamic balance of consistency. This closed-loop control mechanism based on feedback signals enables the system to adapt to the geometric errors of the side beam, achieving uniform and reliable lateral positioning.

[0044] Through the above technical solution, this application achieves multi-point coordination and precise control of lateral clamping force. Because the controller can adjust the clamping force of each clamping station in real time based on the feedback signals from each third sensing element, it not only ensures the consistency of the clamping force at each station but also ensures that the final force value accurately reaches the preset clamping force threshold. This solves the problem of independent operation of each clamping point, uncontrollable and inconsistent force values ​​in traditional tooling. It effectively avoids local extrusion deformation of the workpiece due to excessive clamping force at a single point, or unstable positioning due to insufficient clamping force at a single point, thereby significantly improving the accuracy and reliability of the side beam welding positioning and laying a solid foundation for subsequent high-quality welding.

[0045] Example 7: In one possible implementation, this application also provides a fourth detection unit. This fourth detection unit includes multiple fourth sensing elements distributed along the length of the edge beam. Each fourth sensing element is used to detect the clamping force value at its corresponding clamping station. The fourth sensing elements are the core components for achieving accurate clamping force sensing. Their number and distribution density can be set according to the length specifications of the edge beam and welding process requirements. For example, they can be appropriately densely arranged in key stress areas of the edge beam or near welds to ensure a comprehensive and accurate reflection of the stress state of the edge beam along its length. The fourth sensing elements can be pressure sensors, torque sensors, or other detection devices capable of converting physical force values ​​into electrical signal outputs. Their specific selection and installation method can be flexibly configured according to actual working conditions, and this application does not impose any special limitations on this. By independently setting fourth sensing elements at each clamping station, the system can obtain the specific clamping force value of each clamping point in real time, providing a data foundation for subsequent refined control.

[0046] The controller adjusts the clamping force of each clamping station based on feedback signals from the fourth sensing elements, ensuring that the clamping force at each station remains consistent and reaches the preset clamping force threshold. As the system's decision-making core, the controller has a pre-installed closed-loop control algorithm that continuously receives feedback signals from each fourth sensing element and calculates in real-time the deviation between the actual clamping force at each clamping station and the target setpoint. During adjustment, the controller first executes consistency adjustment logic, comparing the clamping force values ​​at each station and increasing or decreasing the output of the corresponding clamping station's drive mechanism (such as a hydraulic valve or servo motor) to eliminate force differences between stations. This ensures that the edge beam receives a uniform downward clamping force along its length, preventing workpiece crushing due to excessive local pressure or positioning failure due to insufficient pressure. After achieving consistent force values, the controller further executes threshold attainment adjustment logic, synchronously increasing the clamping force at each station to the preset clamping force threshold. The preset clamping force threshold is the minimum clamping force calculated based on the material properties, cross-sectional dimensions, and welding heat input of the edge beam. Its typical relationship can be expressed as: ; in, To preset the clamping force threshold, The yield strength of the edge beam material at the welding temperature. This represents the effective contact area between the clamping head and the edge beam. For safety factor and .

[0047] Through the above closed-loop adjustment, the controller can dynamically correct the force fluctuations caused by welding thermal deformation or external disturbances, ensuring that the clamping force of each clamping station is always maintained at a preset and uniform level throughout the welding process, thereby effectively suppressing the welding deformation of the side beam and ensuring the welding accuracy and product quality.

[0048] Example 8: In one possible implementation, this application also provides a pressure compensation safety monitoring and fault diagnosis logic. The controller is further configured to: when triggering a pressure compensation operation, simultaneously compare the tightening force sensed by the third detection unit and the compressive force sensed by the fourth detection unit; if either force value fails to reach the corresponding preset threshold after pressure compensation, it is determined that the side beam has irreversible deformation and a shutdown alarm is triggered.

[0049] The pressure replenishment safety monitoring and fault diagnosis logic is a necessary safety supplement to the aforementioned pressure replenishment function. During the welding process, when the controller determines that the force value is lower than the preset threshold based on the feedback signal from the third or fourth detection unit and automatically triggers the pressure replenishment operation, the controller does not simply execute the drive command, but simultaneously initiates a composite monitoring and judgment process. During or after the pressure replenishment action is executed, the controller immediately acquires the real-time clamping force data fed back by the third detection unit and the real-time pressing force data fed back by the fourth detection unit, and compares these two force values ​​with their respective preset thresholds. This comparison process aims to evaluate the effectiveness of the pressure replenishment operation, that is, to determine whether the system's active intervention has successfully restored the required positioning constraint force. If the comparison result shows that both the clamping force and the pressing force have been restored to the corresponding preset threshold range, the pressure replenishment is determined to be successful, and the system continues to maintain the current welding and monitoring state.

[0050] Conversely, if the comparison results show that any force value still cannot reach the corresponding preset threshold after the pressure compensation operation, it means that although the actuator has output drive commands, the physical state of the workpiece cannot be corrected by conventional clamping or pressing actions. This phenomenon of force control failure usually indicates that the edge beam has undergone plastic deformation beyond its elastic range under the action of welding heat input, i.e., irreversible deformation. For example, the edge beam has undergone severe torsion or buckling, causing the clamping mechanism to be unable to apply effective constraint force. Based on this physical evidence, the controller will determine that the edge beam has irreversible deformation. At this time, in order to avoid continuing to forcibly compensate for pressure under the condition that the workpiece is severely deformed, which would cause mechanical damage to the fixture equipment, or cause the welding defects to be further expanded and the workpiece to be scrapped, the controller will immediately trigger a shutdown alarm. The shutdown alarm operation includes, but is not limited to, immediately cutting off the welding power supply, stopping the action of all clamping and pressing drive mechanisms, and issuing an audible and visual alarm to the operator to prompt manual intervention. Through the above technical solution, this application realizes intelligent identification and automatic safety response to severe deformation conditions during the welding process, effectively improving the system's operational safety and fault diagnosis capabilities, and avoiding equipment damage and ineffective processing.

[0051] Example 9: In one alternative implementation, such as Figure 4The diagram shown is a flowchart of a side beam welding positioning method provided in an embodiment of this application. The method includes the following steps: Step S401: S1, Reference Establishment: The reference positioning module establishes a global positioning reference. The first detection unit senses the status of the positioning reference surface of each positioning station. When the first detection unit confirms that each positioning reference surface is coplanar and the position deviation is less than the preset deviation threshold, a reference establishment completion signal is generated.

[0052] The benchmark establishment process aims to construct a unified and high-precision spatial reference system for subsequent welding positioning operations. The benchmark positioning module is responsible for constructing the global positioning benchmark, whose physical carrier typically includes a high-rigidity positioning base and a precision-machined positioning benchmark surface. The first detection unit consists of multiple first sensing elements distributed along the length of the edge beam, such as displacement sensors, contact probes, or photoelectric sensors, used to collect real-time spatial position data of the positioning benchmark surface at the corresponding positioning station. Through the fusion processing of multi-point sensing data, a continuous data field reflecting the flatness of the benchmark surface is constructed. The controller performs calculations and analysis on the above position data. When it confirms that each positioning benchmark surface meets the coplanarity condition and the position deviation is lower than the preset deviation threshold, it determines that the benchmark establishment is qualified, and the first detection unit outputs a benchmark establishment completion signal. The preset deviation threshold is set according to the design accuracy requirements of the edge beam and the tolerance range allowed by the welding process. For example, it can refer to national standards or the company's internal welding quality specifications. For a 12-meter-long edge beam, this threshold can be set to 0.1mm to 0.2mm. Through multi-point sensing and coplanarity verification mechanisms, the geometric accuracy of the global positioning benchmark is ensured, eliminating the cumulative positioning error caused by benchmark deviation at the source.

[0053] Step S402: S2, Support Setting: After receiving the baseline establishment completion signal, the controller calculates the target support height of each support station according to the side beam section parameters and drives the adjustment. After the second detection unit confirms that each support surface is on the same horizontal plane, it generates a support baseline establishment signal.

[0054] The support setting stage provides a horizontal support benchmark that conforms to the design elevation for the edge beam, ensuring that the web or flange of the edge beam is at the correct welding height. Upon receiving the benchmark establishment completion signal, the controller initiates the logic calculation and drive control of this stage, demonstrating a step-by-step linkage control logic. Based on the read edge beam cross-sectional parameters (such as web height and flange width) and the pre-entered system zero-point elevation, the controller calculates the required vertical target height for each support station and sends drive commands to the support module to adjust each support station to the target height. The second detection unit contains multiple second sensing elements distributed along the length of the edge beam, used to monitor the actual height of each support station in real time. When the second detection unit confirms that all support surfaces are on the same horizontal plane, i.e., the height difference between each support station is controlled within the allowable levelness error range, a support benchmark establishment signal is generated. This levelness error threshold can be set according to the welding accuracy level, for example, from 0.05mm to 0.1mm. By accurately calculating the cross-sectional parameters and confirming the horizontal plane of the second detection unit, it is ensured that the supporting foundation of the side beam is in an ideal horizontal state before placement, effectively avoiding the twisting or uneven stress of the side beam caused by uneven supporting surface.

[0055] Step S403: S3, Positioning Confirmation: Place the side beam on each support position. The second detection unit senses the change in load-bearing state and generates a side beam positioning confirmation signal after verifying that the side beam is in the correct position.

[0056] The positioning confirmation step is used to determine whether the side beam has been correctly and stably placed on the support module. After the side beam is placed in its adjusted support position using hoisting equipment, the second detection unit senses changes in the load-bearing state through various second sensing elements, such as detecting sudden changes in the pressure sensor values ​​or the contact signals of the displacement sensor, to confirm that the side beam has established effective physical contact with each support position. Verifying that the side beam is in the correct position involves not only confirming that the side beam has been placed, but also detecting whether there is any offset in the relative position of the side beam on the support surface. Based on the load distribution data fed back by the second detection unit, the controller analyzes whether the center of gravity of the side beam is within the preset support area and checks for any abnormal working conditions such as local suspension or excessive stress at a single point. When the second detection unit confirms that the load borne by all support positions is within the preset range and the load distribution conforms to the side beam placement pattern, it determines that the side beam is correctly positioned and generates a side beam positioning confirmation signal. This signal serves as a prerequisite for subsequent lateral tightening operations, ensuring that lateral constraints are applied only when the side beam is stably positioned.

[0057] Step S404: S4, Lateral Tightening: After receiving the side beam positioning confirmation signal, the controller drives each tightening station to apply lateral tightening force. The first detection unit senses the fitting status in real time, and the third detection unit senses the tightening force value in real time. The lateral positioning completion signal is generated after the first detection unit confirms that the fit is complete and the third detection unit confirms that the tightening force has reached the preset threshold.

[0058] The lateral clamping step aims to eliminate the gap between the side of the edge beam and the positioning reference surface, and to firmly constrain the edge beam to the reference side, preventing lateral displacement during welding. After receiving the edge beam positioning confirmation signal, the controller triggers the lateral clamping module to operate, driving each clamping station to apply a lateral clamping force towards the reference positioning module to the edge beam. During this process, the first and third detection units simultaneously enter real-time monitoring mode: the first detection unit provides real-time feedback on the fit gap status between the side of the edge beam and the positioning reference surface; the third detection unit monitors the clamping force value applied by each clamping station in real-time through various third sensing elements (such as pressure sensors or torque sensors). This process continues until two judgment conditions are met: first, the first detection unit confirms that the side of the edge beam is completely fitted with the positioning reference surface, that is, all fit gaps are zero or less than the preset micro-gap threshold; second, the third detection unit confirms that the clamping force value of all clamping stations has reached the preset clamping force threshold. The preset clamping force threshold is determined based on the yield strength and welding heat deformation resistance of the edge beam material. For example, for edge beams with specific cross-sectional specifications and materials, this value can be set within the range of 500N to 2000N. When the above conditions are met simultaneously, the controller generates a lateral positioning completion signal. This closed-loop control strategy based on dual confirmation of the contact state and force value significantly improves the rigidity and accuracy of lateral positioning.

[0059] Step S405: S5, Pressing and Fixing: After receiving the lateral positioning completion signal, the controller drives each pressing station to press the side beam from above. The fourth detection unit senses the pressing force value in real time until the fourth detection unit confirms that the pressing force of each pressing station has reached the preset threshold and then generates a positioning completion signal.

[0060] The clamping and fixing process applies vertical pressure from above to firmly press the side beam onto the support module, forming a complete six-point spatial positioning constraint in conjunction with lateral clamping. Upon receiving the lateral positioning completion signal, the controller activates the clamping module, driving each clamping station to move downwards to contact the upper surface of the side beam and apply pressure. The fourth detection unit, composed of multiple fourth sensing elements, is used to detect the actual clamping force value at each clamping station in real time. During the clamping process, the controller continuously monitors the feedback signal from the fourth detection unit and dynamically adjusts the output force of each clamping station according to a preset control algorithm to ensure uniform force distribution at each point. The controller generates a positioning completion signal, marking the end of the side beam welding positioning process, once the fourth detection unit confirms that the clamping force value at all clamping stations has reached the preset clamping force threshold. The preset clamping force threshold is typically higher than the preset clamping force threshold to overcome vertical warping deformation generated during welding; for example, it can be set to 800N to 3000N. At this point, the side beam is completely fixed within a rigid frame consisting of a reference positioning module, a support module, a lateral clamping module, and a pressing module, providing the necessary physical constraints for subsequent high-quality welding.

[0061] Step S406: S6, Welding Monitoring and Pressure Replenishment: During the welding process, the third and fourth detection units continuously sense the clamping force and pressure status. When the force value sensed by any detection unit is lower than the corresponding preset threshold, the controller automatically triggers pressure replenishment at the corresponding station. During the pressure replenishment process, the first detection unit synchronously monitors the bonding status. If the bonding status is damaged, an alarm is triggered and welding is stopped.

[0062] The welding monitoring and pressure replenishment process constitutes the closed-loop control core of this embodiment, aiming to solve the problem of clamping force relaxation caused by workpiece deformation due to welding heat input. After the welding operation begins, the third and fourth detection units continuously monitor the clamping and pressing forces in real time. Given that the welding thermal cycle causes material expansion and contraction, leading to a decrease in clamping force, when the force value sensed by any detection unit is lower than the corresponding preset threshold (i.e., lower than the force value standard set in step S4 or S5), the controller determines that the current positioning constraint is insufficient and automatically triggers the pressure replenishment action at the corresponding station. The controller drives the corresponding actuator to increase the output force until the force value returns to within the preset threshold range. During the pressure replenishment process, the first detection unit simultaneously monitors the bonding state to prevent the pressure replenishment operation from introducing additional lateral forces that could forcibly push the side beam and disrupt its bonding with the reference surface. If the first detection unit senses that the bonding state is disrupted during the pressure replenishment process, such as a sudden increase in the bonding gap or exceeding the safety limit, the controller immediately determines that the system is abnormal or that the side beam has undergone irreversible deformation, triggers an alarm, and stops welding. This dynamic compensation mechanism of monitoring, pressure replenishment, and verification extends positioning control from static pre-process preparation to the entire dynamic welding process, effectively suppressing welding deformation and ensuring the stability of the weld assembly dimensions.

[0063] The aforementioned technical features work in close coordination through signal flow and logical judgment to form a closed-loop control system for the welding and positioning of the side beam. The benchmark establishment step provides a unified geometric reference for subsequent steps. The support setting step constructs a horizontal support benchmark based on this reference. The positioning confirmation step ensures the workpiece accurately falls onto the support benchmark. The lateral clamping and pressing steps apply constraints sequentially from the lateral and vertical directions, and the detection unit confirms the constraints are in place. The welding monitoring and pressure replenishment steps maintain the effectiveness of the constraints throughout the welding process. Each step receives the completion signal of the previous step as a start condition through the controller, achieving strict step-by-step linkage. The sensing signals from the detection unit not only determine the completion of a step but also serve as control commands to trigger the next action or pressure replenishment action. This collaborative mechanism eliminates the drawbacks of fragmented steps and uncontrollable states in traditional manual positioning methods, ensuring the positioning accuracy and stability of the side beam throughout the welding process and effectively improving the final welding quality.

[0064] Example 10: One possible implementation is, such as Figure 5As shown, this application also provides a specific process for applying tightening and pressing forces sequentially from the middle to both ends in the edge beam welding positioning method. The method includes the following steps: Step S501: In step S4, the lateral tightening force is applied in an increasing order from the middle position of the side beam to both ends along the length direction. The tightening position at the middle position reaches the preset tightening force threshold before the tightening positions at both ends.

[0065] The execution logic of the lateral clamping module follows a spatial timing strategy of prioritizing the center and gradually expanding. First, the geometric center position along the length of the side beam is identified and defined as the starting point of the clamping action. When the controller executes the lateral clamping command, it prioritizes driving the clamping station located at this center position to output lateral force. This action aims to first fix the geometric center of the side beam along its length onto a predetermined theoretical axis, thereby establishing a stable positioning core in the global coordinate system. During the application of clamping force at the clamping station in the center position, the controller synchronously receives force value signals from the third detection unit in real time. Once the clamping force value at the center position reaches the preset clamping force threshold and is confirmed as stable, the controller sequentially triggers the clamping stations at adjacent positions to execute the clamping action, proceeding from the center outwards. For example, if there is an odd number of clamping stations along the length of the side beam, the station located at the very center is directly activated; if there is an even number, two stations symmetrically located along the centerline are activated simultaneously as the equivalent starting point of the center position. Subsequently, the clamping process is gradually advanced longitudinally towards both ends of the edge beam, ensuring that the clamping stations located at both ends finally reach the preset clamping force threshold. This sequential application logic, by first establishing a rigid constraint in the middle and then extending it to both ends, can effectively eliminate the inherent bending and wave deformation of long edge beams caused by their own weight or transportation, and prevent cumulative displacement errors at the other end due to forced clamping from one end.

[0066] Step S502: In step S5, the clamping force is applied sequentially from the middle of the side beam along its length to both ends, and the clamping sequence is consistent with the tightening sequence in step S4.

[0067] The execution sequence of the clamping module and the lateral clamping module maintains spatial synchronization. When the controller receives the lateral positioning completion signal and triggers the clamping and fixing operation, it strictly reuses the spatial sequence from the middle to both ends established in step S4. In the specific execution process, the controller first retrieves the coordinates of the clamping station at the middle position determined during the lateral clamping process, and drives the clamping station corresponding to that coordinate or located in the same longitudinal section to act first. By prioritizing the clamping of the middle area of ​​the side beam, the lateral clamping force can be combined in the vertical direction to firmly lock the middle section of the side beam onto the support surface of the support module, forming a stable central node for three-dimensional clamping. After the clamping force applied by the clamping station at the middle position reaches the preset clamping force threshold, the controller drives the subsequent clamping stations to both ends in sequence according to the aforementioned clamping sequence. Ensuring the consistency between the clamping sequence and the clamping sequence guarantees that any section of the side beam in the length direction is first laterally clamped in place before the upper clamping and fixing is performed. This collaborative operation method avoids the rebound or displacement of the established lateral positioning caused by disordered clamping sequence, ensuring that the side beam remains in close contact with the reference positioning module throughout its entire length, thereby minimizing residual stress and deformation before welding.

[0068] The aforementioned technical features achieve coordinated deformation control during the positioning process by strictly defining the spatial execution sequence of lateral clamping and pressing. Applying constraint forces sequentially from the middle to both ends allows the deformation of long-length side beams to be gradually released and corrected towards the free end, avoiding error accumulation caused by unidirectional force application, thus ensuring high precision and high reliability in welding positioning.

[0069] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A side beam welding positioning system, characterized in that, include: The reference positioning module has multiple positioning stations arranged along the length of the side beam, and each positioning station is equipped with a first detection unit for sensing the fitting status. The support module is located on one side of the reference positioning module and has multiple support stations arranged along the length of the side beam. Each support station is equipped with a second detection unit for sensing the load-bearing status. The lateral clamping module is located on the side of the support module opposite to the reference positioning module. Multiple clamping stations are arranged along the length of the side beam. Each clamping station is equipped with a third detection unit for sensing the clamping force status. The clamping module has multiple clamping stations arranged along the length of the side beam, and each clamping station is equipped with a fourth detection unit for sensing the clamping force status. The controller, connected to each detection unit, is configured to execute a hierarchical linkage logic: the controller triggers support setting only after the first detection unit confirms the establishment of the reference; it triggers positioning confirmation only after the second detection unit confirms that all support surfaces are on the same horizontal plane; it triggers lateral tightening only after the second detection unit verifies positioning; it triggers pressing only after the first detection unit confirms fit and the third detection unit confirms that the pressing force reaches a preset threshold; and it generates a positioning completion signal after the fourth detection unit confirms that the pressing force reaches a preset threshold. This forms a hierarchical linkage positioning chain of reference establishment, support setting, positioning confirmation, lateral tightening, and pressing fixation. There is a condition triggering mechanism between adjacent levels, executed by the controller and based on the sensing signals of the detection units.

2. The system according to claim 1, characterized in that, The controller is also configured to continuously receive sensing signals from the third and fourth detection units during the welding process. When the clamping force value sensed by the third detection unit is lower than the preset clamping force threshold, the corresponding clamping station is automatically triggered to compensate for the pressure. When the clamping force value sensed by the fourth detection unit is lower than the preset clamping force threshold, the corresponding clamping station is automatically triggered to compensate for the pressure. During the compensation for pressure, the controller continuously monitors the signal from the first detection unit. If the first detection unit senses that the bonding state has been damaged, it triggers an alarm and stops welding.

3. The system according to claim 1, characterized in that, When performing lateral tightening, the controller drives each tightening station in a sequential order from the middle position of the side beam to both ends, with the tightening station at the middle position reaching the preset tightening force threshold before the tightening stations at both ends; when performing compression, the controller drives each compression station in a sequential order from the middle position of the side beam to both ends, and the compression sequence is consistent with the tightening sequence.

4. The system according to claim 1, characterized in that, The first detection unit includes multiple first sensing elements distributed along the length of the side beam. Each first sensing element is used to detect the fitting gap between the side of the side beam and the positioning reference surface at the corresponding positioning station. When the fitting gap detected by all the first sensing elements is less than a preset gap threshold, a positioning signal is output.

5. The system according to claim 1, characterized in that, The second detection unit includes multiple second sensing elements distributed along the length of the side beam. Each second sensing element is used to detect the load-bearing status and load capacity at the corresponding support station. When the load capacity detected by all the second sensing elements is greater than the preset load threshold and the load capacity distribution deviation is less than the preset deviation threshold, the side beam positioning confirmation signal is output.

6. The system according to claim 1, characterized in that, The third detection unit includes multiple third sensing elements distributed along the length of the side beam. Each third sensing element is used to detect the clamping force value at the corresponding clamping station. The controller adjusts the clamping force of each clamping station according to the feedback signal of each third sensing element so that the clamping force of each clamping station is consistent and reaches the preset clamping force threshold.

7. The system according to claim 1, characterized in that, The fourth detection unit includes multiple fourth sensing elements distributed along the length of the side beam. Each fourth sensing element is used to detect the clamping force value at the corresponding clamping station. The controller adjusts the clamping force of each clamping station according to the feedback signal of each fourth sensing element so that the clamping force of each clamping station is consistent and reaches the preset clamping force threshold.

8. The system according to claim 2, characterized in that, The controller is also configured to: when triggering the pressure replenishment operation, simultaneously compare the top clamping force sensed by the third detection unit and the pressing force sensed by the fourth detection unit; if either force value still cannot reach the corresponding preset threshold after pressure replenishment, it is determined that the side beam has irreversible deformation and a shutdown alarm is triggered.

9. A method for positioning edge beams during welding, employing the edge beam welding positioning system as described in any one of claims 1-8, characterized in that, Includes the following steps: S1. Reference Establishment: The reference positioning module establishes a global positioning reference. The first detection unit senses the status of the positioning reference surface of each positioning station. When the first detection unit confirms that the positioning reference surfaces are coplanar and the position deviation is less than a preset deviation threshold, a reference establishment completion signal is generated. S2, Support Setting: After receiving the baseline establishment completion signal, the controller calculates the target support height of each support station according to the side beam section parameters and drives the adjustment. After the second detection unit confirms that each support surface is on the same horizontal plane, it generates a support baseline establishment signal. S3. Positioning Confirmation: Place the side beam on each support station. The second detection unit senses the change in load-bearing state and generates a side beam positioning confirmation signal after verifying that the side beam is in the correct position. S4. Lateral Tightening: After receiving the side beam positioning confirmation signal, the controller drives each tightening station to apply lateral tightening force. The first detection unit senses the fitting status in real time, and the third detection unit senses the tightening force value in real time. The lateral positioning completion signal is generated after the first detection unit confirms that the fit is complete and the third detection unit confirms that the tightening force reaches the preset threshold. S5. Pressing and fixing: After receiving the lateral positioning completion signal, the controller drives each pressing station to press the side beam from above. The fourth detection unit senses the pressing force value in real time until the fourth detection unit confirms that the pressing force of each pressing station has reached the preset threshold and then generates a positioning completion signal. S6. Welding monitoring and pressure replenishment: During the welding process, the third and fourth detection units continuously sense the clamping force and pressure state. When the force value sensed by any detection unit is lower than the corresponding preset threshold, the controller automatically triggers pressure replenishment at the corresponding station. During the pressure replenishment process, the first detection unit synchronously monitors the bonding state. If the bonding state is damaged, an alarm is triggered and welding is stopped.

10. The method according to claim 9, characterized in that, In step S4, the lateral tightening force is applied in an increasing order from the middle position of the side beam to both ends. The tightening station at the middle position reaches the preset tightening force threshold first, and the tightening stations at both ends reach the preset tightening force threshold later. In step S5, the clamping force is applied in an increasing order from the middle position of the side beam to both ends, and the clamping order is the same as the tightening order in step S4.

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