Bridge welding device

Abstract

The bridge welding device comprises a guide rail and a welding industrial robot, the guide rail is of an I-shaped integrated structure formed by an upper rail steel plate, a toothed plate and a lower rail steel plate which are sequentially connected from top to bottom, and racks are symmetrically arranged on the two sides of the toothed plate; the welding industrial robot comprises two advancing gears symmetrically arranged at the top of an industrial robot shell, the advancing gears are connected with racks on the two sides of a toothed plate in a meshed mode, a motor used for driving rotating shafts is arranged in the industrial robot shell, and transmission gears meshed with each other are arranged between the two rotating shafts. The bottom of the industrial robot shell is connected with a first hydraulic rod through a V-shaped supporting rod, a welding gun is installed on the first hydraulic rod, and the first hydraulic rod is connected with the bottom of the industrial robot shell through a second hydraulic rod. According to the utility model, the I-shaped guide rail is matched with the meshed advancing gear, so that the welding industrial robot can continuously and stably move along a 30-50m long seam, and the problems of frequent welding and positioning interruption of a traditional robot are solved.

Description

Technical Field

[0001] This utility model relates to the field of welding technology, specifically a bridge welding device. Background Technology

[0002] With the large-scale application of steel structure bridges, the welding quality of the long welds between the U-shaped bridge support plate and the bridge deck directly affects the overall structural strength of the bridge. In current engineering practice, industrial robot welding systems still face significant technical bottlenecks when dealing with such special working conditions: First, the length of the U-shaped support plate components generally reaches 30-50 meters. Limited by the working radius of the industrial robot body (usually no more than 3 meters), traditional welding industrial robots cannot achieve continuous welding operations, requiring frequent equipment repositioning, leading to defects such as porosity and incomplete fusion at the weld joint. Second, the welding joint is located in the overhead welding position formed at the bottom of the bridge, requiring the end effector of the welding torch to maintain a precise attitude angle of 45°±5° during its movement. However, existing six-axis industrial robots struggle to achieve long-distance attitude stability control due to accumulated errors in joint movement. Utility Model Content

[0003] The purpose of this invention is to provide a bridge welding device that has the advantages of continuous long-distance high-precision welding and precise attitude control of the welding gun, thus solving the problems in the prior art.

[0004] To achieve the above objectives, this utility model provides the following technical solution:

[0005] A bridge welding device includes a guide rail and a welding industrial robot. The guide rail is an I-shaped integrated structure composed of an upper rail steel plate, a toothed plate, and a lower rail steel plate connected sequentially from top to bottom. Toothed racks are symmetrically arranged on both sides of the toothed plate. The welding industrial robot includes two symmetrically arranged travel gears on the top of the robot housing, which mesh with the toothed racks on both sides of the toothed plate. A rotating shaft is located at the bottom of the travel gears. A motor for driving the rotating shaft is located inside the robot housing. A transmission gear meshes between the two rotating shafts. A first hydraulic rod is connected to the bottom of the robot housing via a V-shaped support rod. A welding gun is mounted on the first hydraulic rod. The first hydraulic rod and the bottom of the robot housing are connected via a second hydraulic rod.

[0006] Preferably, the upper rail steel plate is fixed to the bottom surface of the bridge deck by welding or bolting.

[0007] Preferably, the support rod has a "V" shaped structure, and the two upper ends of the support rod are pivotally connected to the industrial robot housing.

[0008] Preferably, a first hydraulic rod is provided at the bottom of the support rod, the axis of the first hydraulic rod is perpendicular to the plane of the support rod, the cylinder end of the first hydraulic rod is fixedly connected to the lower end of the support rod, and the upper end of the first hydraulic rod is connected to a welding gun.

[0009] Preferably, the two ends of the second hydraulic rod are pivotally connected to the outer peripheral wall of the first hydraulic rod and the bottom surface of the industrial robot housing, respectively.

[0010] Preferably, the first hydraulic rod is a servo hydraulic cylinder with a stroke of 500mm, and the second hydraulic rod is a servo hydraulic cylinder with a stroke of 200mm.

[0011] Preferably, the base of the welding gun is provided with a dual-axis tilt sensor for monitoring the angle between the welding gun axis and the horizontal plane.

[0012] Preferably, the industrial robot housing is equipped with a PLC controller, which is connected to a dual-axis tilt sensor, a motor, a first hydraulic rod, a welding gun, and a second hydraulic rod.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] 1. This utility model achieves continuous and stable movement of welding industrial robots along 30-50 meter long joints through the cooperation of I-shaped guide rails and meshing travel gears, solving the problem of frequent positioning interruptions caused by the working radius limitation of traditional robots.

[0015] 2. This utility model is based on a closed-loop control system with dual hydraulic rods and an inclination sensor. The first hydraulic rod is used for height adjustment, and the second hydraulic rod is used for stroke angle compensation. The angle between the welding gun and the horizontal plane is adjusted in real time to ensure that the overhead welding angle is stable at 45°±5°, improving the consistency of penetration depth by 30% and significantly reducing porosity and incomplete fusion defects. The V-shaped support rod and the industrial robot shell form a three-point stabilizing structure to counteract the lateral displacement caused by wind load and vibration, reduce the amplitude of welding gun vibration, and is suitable for the complex working conditions of open-air bridge construction. Attached Figure Description

[0016] Figure 1 This is an isometric view of the overall structure of this utility model;

[0017] Figure 2 This is a bottom view of the overall structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the overall structure and U-shaped bridge support plate of this utility model.

[0019] In the diagram: 1. Upper rail steel plate; 2. Toothed plate; 3. Lower rail steel plate; 4. Traveling gear; 5. Bridge deck; 6. Welding industrial robot; 7. U-shaped bridge auxiliary plate; 8. Industrial robot shell; 9. Welding gun; 10. Rotating shaft; 11. Motor; 12. Transmission gear; 13. Support rod; 14. First hydraulic rod; 15. Second hydraulic rod. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] To address the limitations of existing technologies, such as the inability to perform continuous, long-distance, high-precision welding and the inability to precisely control the welding torch's attitude, the following technical solution is proposed. Please refer to [link / reference]. Figure 1-3 ;

[0022] A bridge welding device includes a guide rail and a welding industrial robot 6. The guide rail is located on one side of a U-shaped bridge support plate 7 and extends in the same direction as the U-shaped bridge support plate 7. The welding industrial robot 6 is connected below the guide rail. The welding industrial robot 6 moves at a constant speed along the direction of the guide rail to weld the joint between the U-shaped bridge support plate 7 and the bridge deck 5.

[0023] The guide rail includes an upper rail steel plate 1, a toothed plate 2, and a lower rail steel plate 3, with a length between 30 and 50 meters. The upper rail steel plate 1, toothed plate 2, and lower rail steel plate 3 are connected sequentially from top to bottom to form an integral structure. The longitudinal cross-section of the upper rail steel plate 1, toothed plate 2, and lower rail steel plate 3 is I-shaped. A row of toothed racks is provided on both sides of the toothed plate 2. The upper rail steel plate 1 is installed on the bottom surface of the bridge deck 5 by welding or bolting. A welding industrial robot 6 is installed directly below the lower rail steel plate 3.

[0024] The welding industrial robot 6 includes an industrial robot housing 8 and a welding gun 9. Two symmetrical traveling gears 4 are arranged on the top of the industrial robot housing 8. The traveling gears 4 are located on both sides of the toothed plate 2 and mesh with the rack. A rotating shaft 10 is arranged at the center of the bottom surface of the traveling gear 4. The rotating shaft 10 passes through the industrial robot housing 8 and is rotatably connected to it. A motor 11 is arranged inside the industrial robot housing 8. The motor 11 is connected to one of the rotating shafts 10. A transmission gear 12 is arranged on each rotating shaft 10. The two transmission gears 12 mesh with each other.

[0025] Specifically, motor 11 drives the rotating shaft 10 connected to motor 11 to rotate, and the rotating shaft 10 drives the traveling gear 4 connected to it to rotate. At the same time, the rotating shaft 10 drives another rotating shaft 10 and the traveling gear 4 to rotate in opposite directions through two transmission gears 12. The industrial robot housing 8 moves on the guide rail through the meshing of the traveling gear 4 and the rack. The meshing transmission of the transmission gears 12 can effectively reduce the synchronization error of the two rotating shafts 10 and prevent the traveling gear 4 from deviating from its path due to asynchronous speed. The traveling gear 4 moves by meshing with the toothed plate 2, which effectively prevents the industrial robot housing 8 from slipping on the guide rail surface and causing positioning drift.

[0026] The bottom surface of the industrial robot housing 8 is provided with a support rod 13. The support rod 13 has a "V" shaped structure. The two upper ends of the support rod 13 are pivotally connected to the industrial robot housing 8. The support rod 13 and the bottom surface of the industrial robot housing 8 form a stable triangular structure, thereby improving the connection stability, reducing the adverse effects of wind on outdoor operations, and preventing equipment vibration from causing the welding arc to shift.

[0027] A first hydraulic rod 14 is provided at the bottom of the support rod 13. The axis of the first hydraulic rod 14 is perpendicular to the plane of the support rod 13. The cylinder end of the first hydraulic rod 14 is fixedly connected to the lower end of the support rod 13. A welding gun 9 is connected to the upper end of the first hydraulic rod 14. A second hydraulic rod 15 is also provided between the first hydraulic rod 14 and the industrial robot housing 8. The two ends of the second hydraulic rod 15 are pivotally connected to the outer peripheral wall of the first hydraulic rod 14 and the bottom surface of the industrial robot housing 8, respectively.

[0028] Specifically, the first hydraulic rod 14 is a servo hydraulic cylinder with a stroke of 500mm, which adjusts the height of the welding gun 9 by extension and retraction. The relative height of the upper end of the welding gun 9 is adjusted by the extension and retraction of the first hydraulic rod 14. The second hydraulic rod 15 is a hydraulic rod with a stroke of 200mm, which controls the deflection angle of the welding gun 9, thereby adjusting the angle between the welding gun 9 and the U-shaped bridge auxiliary plate 7, so that the angle between the welding gun 9 and the side wall of the U-shaped bridge auxiliary plate 7 is 45°, and the error is controlled within 5°.

[0029] A dual-axis tilt sensor is integrated at the base of the welding gun 9 to monitor the tilt angle between the axis of the welding gun 9 and the horizontal plane in real time. The sensor signal is connected to the PLC controller inside the industrial robot housing 8 and compared with the preset 45° reference value to generate a closed-loop control signal. The PLC controller is also connected to the first hydraulic rod 14, the welding gun 9, the second hydraulic rod 15 and the motor 11.

[0030] Working principle: During system initialization, the parallelism between the guide rail and the seam is calibrated by a laser positioning device. The motor 11 is started, driving the rotating shaft 10 connected to the motor 11 to rotate. The rotating shaft 10 drives the traveling gear 4 connected to it to rotate. At the same time, the rotating shaft 10 drives another rotating shaft 10 and the traveling gear 4 to rotate in opposite directions through two transmission gears 12. The meshing of the traveling gear 4 and the rack drives the industrial robot shell 8 to move on the guide rail. The traveling gear 4 moves at a constant speed of 0.3m / min. The PLC controller synchronously calculates the theoretical welding position coordinates. When the tilt sensor detects that the actual angle θ is greater than 45°, the stroke of the second hydraulic rod 15 is extended, and the first hydraulic rod 14 is adjusted to make the welding point coincide with the weld. When the tilt sensor detects that the actual angle θ is less than 40°, the stroke of the second hydraulic rod 15 is shortened, and the first hydraulic rod 14 is adjusted to make the welding point coincide with the weld.

[0031] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0032] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention.

Claims

1. A bridge welding device comprising a guide rail and a welding industrial robot (6), characterized in that, The guide rail is formed by an I-shaped integrated structure consisting of an upper rail steel plate (1), a toothed plate (2), and a lower rail steel plate (3) connected from top to bottom. The toothed plate (2) is symmetrically provided with racks on both sides. The welding industrial robot (6) includes two symmetrically arranged travel gears (4) on the top of the industrial robot housing (8). The travel gears (4) are meshed with the racks on both sides of the toothed plate (2). The travel gears (4) are provided with a rotating shaft (10) at the bottom. The industrial robot housing (8) is provided with a motor (11) for driving the rotating shaft (10). The two rotating shafts (10) are provided with a transmission gear (12) that meshes with each other. The bottom of the industrial robot housing (8) is connected to a first hydraulic rod (14) through a V-shaped support rod (13). A welding gun (9) is installed on the first hydraulic rod (14). The first hydraulic rod (14) and the bottom of the industrial robot housing (8) are connected through a second hydraulic rod (15).

2. A bridge welding device according to claim 1, characterized in that The upper rail steel plate (1) is fixed to the bottom surface of the bridge deck (5) by welding or bolting.

3. A bridge welding device according to claim 2, characterized in that The support rod (13) has a "V" shaped structure, and the two upper ends of the support rod (13) are pivotally connected to the industrial robot housing (8).

4. A bridge welding device according to claim 3, characterized in that The bottom of the support rod (13) is provided with a first hydraulic rod (14). The axis of the first hydraulic rod (14) is perpendicular to the plane where the support rod (13) is located. The cylinder end of the first hydraulic rod (14) is fixedly connected to the lower end of the support rod (13). The upper end of the first hydraulic rod (14) is connected to a welding gun (9).

5. A bridge welding device according to claim 4, characterised in that The two ends of the second hydraulic rod (15) are pivotally connected to the outer peripheral wall of the first hydraulic rod (14) and the bottom surface of the industrial robot housing (8).

6. A bridge welding device according to claim 5, characterised in that The first hydraulic rod (14) is a servo hydraulic cylinder with a stroke of 500 mm, and the second hydraulic rod (15) is a servo hydraulic cylinder with a stroke of 200 mm.

7. A bridge welding device according to claim 6, characterised in that The base of the welding gun (9) is equipped with a dual-axis tilt sensor for monitoring the angle between the axis of the welding gun (9) and the horizontal plane.

8. A bridge welding device according to claim 7, characterized in that The industrial robot housing (8) is equipped with a PLC controller, which is connected to the dual-axis tilt sensor, motor (11), first hydraulic rod (14), welding gun (9) and second hydraulic rod (15).

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