An automated welding device for steel structures in confined spaces

Abstract

This invention provides an automated welding device for steel structures in confined spaces, belonging to the field of automated steel structure welding technology. The device includes a welding robot, a fixed base, a translation drive mechanism, a translation base, a vertical turning mechanism, a fixed base support beam, and a locking support. The fixed base is mounted on the fixed base support beam and connected to the internal stiffening plates of the box girder via the locking support. The welding robot is mounted on a robot mounting base, which is hinged to a sliding table, which is mounted on the translation base. The vertical turning mechanism performs a 90-degree vertical turning motion of the welding robot around the hinge point. The translation base is driven by the translation drive mechanism to move along the length of the fixed base inside the box girder. This invention can effectively adapt to welding seams in confined spaces such as those found in steel bridges and other box girder structures.

Description

Technical Field

[0001] This utility model relates to the field of automated welding technology for steel structures, and in particular to an automated welding device for steel structures in confined spaces. Background Technology

[0002] Currently, automated welding of steel structures is rarely used in confined spaces, with manual welding being the most common method. However, due to space constraints, poor ventilation and lighting, traditional manual welding operations suffer from poor working conditions, high safety risks, low efficiency, and difficulty in guaranteeing the stability of weld quality.

[0003] In Chinese patent literature, publication number CN118180737A, publication date June 14, 2024, entitled "Omnidirectional Welding Device and Process Applicable to Confined Steel Structure Spaces", it includes a base, a robotic arm and a welding torch, and the robotic arm adjusts the position of the welding torch by means of a telescopic component of an auxiliary adjustment mechanism.

[0004] Although the device takes into account the application scenario of confined spaces, it lacks an effective moving mechanism, making it difficult to achieve continuous welding operations inside long components such as box beams. Utility Model Content

[0005] To address the aforementioned issues, reduce the labor intensity of welding operations, improve the working environment for personnel, enhance welding quality and efficiency, and reduce safety risks in welding operations, this utility model proposes an automated welding device for steel structures in confined spaces, which can effectively adapt to welding seams in the confined spaces of box beams such as steel bridges.

[0006] The technical solution of this utility model is as follows:

[0007] An automated welding device for steel structures in confined spaces includes a welding robot, a fixed base, a translation drive mechanism, a translation base, a vertical turning mechanism, a fixed base support beam, and locking supports. The fixed base is detachably mounted on the fixed base support beam, and multiple locking supports are installed below the fixed base support beam and connected to the stiffening plates inside the box beam through the locking supports.

[0008] The welding robot is equipped with a welding torch at its front end and is mounted on a robot mounting base. The robot mounting base is hinged to a slide table, which is mounted on a translation base. The robot mounting base is hinged to the translation base, and the slide table moves horizontally. The vertical turning mechanism performs the action of turning the welding robot vertically 90 degrees around the hinge point.

[0009] The translation base is mounted on the fixed base, and the translation drive mechanism drives the translation base to move inside the box beam along the length of the fixed base.

[0010] Furthermore, the translation drive mechanism includes a first drive motor, a first reducer, a first bearing housing, and a first drive screw. The first drive screw is rotatably mounted on one side of the fixed base via the first bearing housing and is connected to the first reducer and the first drive motor. A transmission component is provided on the translation base, and the transmission component is located on the same side as the first drive screw. The transmission component is provided with a threaded hole that mates with the first drive screw.

[0011] Furthermore, the vertical turning mechanism includes a second drive motor, a second reducer, a drive gear, a second drive screw, and a connecting rod. The two ends of the second drive screw are rotatably mounted inside the translation base via second bearing seats. The bottom of the slide is provided with nuts that cooperate with the second drive screw. The output shaft of the second drive motor is connected to the input end of the second reducer. The drive gear is fixedly mounted on the output end of the reducer and meshes with the gear of the second drive screw. One end of the connecting rod is hinged to the robot mounting base, and the other end is hinged to the translation base.

[0012] Furthermore, the translation base and the robot mounting base are respectively provided with a first hinge ear plate, and a hinge hole is opened on the first hinge ear plate. The two ends of the connecting rod are respectively provided with hinge holes, and a pin passes through the hinge holes at both ends of the first hinge ear plate and the connecting rod.

[0013] Furthermore, a second hinge ear plate is provided on the slide, and a hinge hole is opened on the second hinge ear plate. A side plate is assembled on one side of the robot mounting base, and a corresponding hinge hole is opened on the side plate. A pin passes through the second hinge ear plate and the hinge hole on the side plate.

[0014] Furthermore, the fixed base is a concave beam structure, and fixed electromagnets are spaced apart in the groove of the concave beam structure. When energized, they generate magnetism to connect the fixed base with the fixed base support beam.

[0015] Furthermore, the top of the fixed base is provided with a sliding rail, and the bottom of the translation base is connected to the sliding rail via a slider.

[0016] Furthermore, the locking support has a U-shaped structure.

[0017] Furthermore, the locking support and the stiffening plate are fixed together by bolts.

[0018] Furthermore, the welding robot is a six-axis industrial robot.

[0019] The beneficial effects of this utility model are as follows:

[0020] 1. This utility model replaces the traditional manual overhead welding in a confined space, which avoids environmental hazards such as poor ventilation and lighting, high temperature radiation, and reduces safety risks such as electric shock and smoke inhalation.

[0021] 2. In this utility model, the vertical turning mechanism enables the welding robot to rotate 90 degrees to reduce its height. Combined with the horizontal movement of the translation base, it enables the robot to cross partitions and traverse narrow spaces, thus adapting to the welding requirements of complex internal cavity structures.

[0022] 3. In this utility model, the fixed base is connected to the fixed base support beam by an electromagnet. It can be quickly fixed by generating magnetism when energized and can be easily moved after power is cut off, thereby improving the transfer efficiency of the equipment between different sections of the box beam. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the present invention assembled inside the box girder;

[0024] Figure 2 This is a schematic diagram of the structure of this utility model;

[0025] Figure 3 This is another structural schematic diagram of the present invention;

[0026] Figure 4 This is another structural schematic diagram of the present invention;

[0027] Figure 5 This is another structural schematic diagram of the present invention;

[0028] Figure 6 This is another structural schematic diagram of the present invention;

[0029] Figure 7 This is a schematic diagram of the locking support structure in this utility model.

[0030] Reference numerals: 1-Welding robot, 2-Welding torch, 3-Fixed base, 4-Robot mounting base, 5-Slide table, 6-Translation drive mechanism, 7-Translation base, 8-Vertical turning mechanism, 9-Fixed base support beam, 10-Locking support, 11-Firming plate, 12-First drive motor, 13-First reducer, 14-First bearing seat, 15-First drive screw, 16-Transmission component, 17-Second drive motor, 18-Second reducer, 19-Drive gear, 20-Second drive screw, 21-Connecting rod, 22-First hinge lug, 23-Second hinge lug, 24-Side plate, 25-Sliding rail, 26-Electromagnet, 27-Partition. Detailed Implementation

[0031] Example 1

[0032] like Figures 1-7As shown, an automated welding device for a narrow space in a steel structure includes a welding robot 1, a fixed base 3, a translation drive mechanism 6, a translation base 7, a vertical turning mechanism 8, a fixed base support beam 9, and locking supports 10. The fixed base 3 is detachably mounted on the fixed base support beam 9. Multiple locking supports 10 are installed below the fixed base support beam 9 and are connected to the stiffening plates 11 inside the box beam through the locking supports 10.

[0033] The welding robot 1 is equipped with a welding torch 2 at its front end and is mounted on a robot mounting base 4. The robot mounting base 4 is hinged to a slide table 5. The slide table 5 is mounted on a translation base 7. The robot mounting base 4 is hinged to the translation base 7. The slide table 5 moves horizontally and the vertical turning mechanism 8 performs the action of turning the welding robot 1 vertically 90 degrees around the hinge point.

[0034] The translation base 7 is mounted on the fixed base 3 and is driven by the translation drive mechanism 6 to move inside the box beam along the length of the fixed base 3.

[0035] This device, through the coordinated operation of the translation drive mechanism 6 and the vertical turning mechanism 8, enables the welding robot 1 to move flexibly and adjust its posture within the confined space inside the box girder. This overcomes the difficulties of traditional manual welding in confined spaces and the instability of welding quality, thus improving welding efficiency and quality. Furthermore, the device is compact, easy to install, and suitable for welding operations in confined spaces within various steel structures.

[0036] Example 2

[0037] This embodiment further elaborates and supplements the implementation of this utility model based on Embodiment 1.

[0038] The translation drive mechanism 6 includes a first drive motor 12, a first reducer 13, a first bearing seat 14, and a first drive screw 15. The first drive screw 15 is rotatably mounted on one side of the fixed base 3 via the first bearing seat 14 and connects the first reducer 13 and the first drive motor 12. A transmission component 16 is provided on the translation base 7, and the transmission component 16 is located on the same side as the first drive screw 15. The transmission component 16 is provided with a threaded hole that mates with the first drive screw 15.

[0039] When the first drive motor 12 is powered on, the first drive motor 12 in the translation drive mechanism 6 drives the first drive screw 15 to rotate through the first reducer 13. The first drive screw 15 engages with the threaded hole of the transmission component 16 on the translation base 7, converting the rotational motion into the linear motion of the translation base 7, thereby realizing the movement of the translation base 7 on the fixed base 3.

[0040] As an example, translation drive mechanisms 6 are provided on both sides of the fixed base 3.

[0041] The vertical turning mechanism 8 includes a second drive motor 17, a second reducer 18, a drive gear 19, a second drive screw 20, and a connecting rod 21. The two ends of the second drive screw 20 are rotatably mounted inside the translation base 7 through second bearing seats. The bottom of the slide table 5 is provided with a nut that cooperates with the second drive screw 20. The output shaft of the second drive motor 17 is connected to the input end of the second reducer 18. The drive gear 19 is fixedly mounted on the output end of the reducer and meshes with the gear of the second drive screw 20. One end of the connecting rod 21 is hinged to the robot mounting base 4, and the other end is hinged to the translation base 7.

[0042] Furthermore, the translation base 7 and the robot mounting base 4 are respectively provided with a first hinge ear plate 22, and a hinge hole is opened on the first hinge ear plate 22. The two ends of the connecting rod 21 are respectively provided with hinge holes, and a pin passes through the hinge holes at both ends of the first hinge ear plate 22 and the connecting rod 21.

[0043] Furthermore, the slide table 5 is provided with a second hinge ear plate 23, and a hinge hole is opened on the second hinge ear plate 23. A side plate 24 is assembled on one side of the robot mounting base 4, and a corresponding hinge hole is opened on the side plate 24. A pin passes through the hinge hole on the second hinge ear plate 23 and the side plate 24.

[0044] The welding robot 1 is mounted on the robot mounting base 4. The robot mounting base 4 is hinged to the second hinge ear plate 23 on the slide table 5 via the side plate 24, forming a structure that can rotate around the hinge point. The second drive motor 17 is powered on, and the second drive motor 17 in the vertical turning mechanism 8 drives the drive gear 19 to rotate through the second reducer 18. The drive gear 19 meshes with the gear of the second drive screw 20, driving the second drive screw 20 to rotate. The second drive screw 20 cooperates with the nut at the bottom of the slide table 5, converting the rotational motion into the linear motion of the slide table 5, realizing the horizontal movement of the slide table 5 on the translation base 7.

[0045] Meanwhile, one end of the connecting rod 21 is hinged to the robot mounting base 4, and the other end is hinged to the translation base 7. When the slide table 5 moves horizontally under the action of the second drive screw 20, the connecting rod 21 rotates around the hinge point, forcing the robot mounting base 4 to rotate around the hinge point of the slide table 5, producing a vertical flipping action of 90 degrees.

[0046] The fixed base 3 is a concave beam structure, and fixed electromagnets 26 are spaced apart in the groove of the concave beam structure. When energized, they generate magnetism to connect the fixed base 3 with the fixed base support beam 9.

[0047] The fixed base support beam 9 is made of steel with good magnetic permeability. When the electromagnet 26 is powered on, the coil of the electromagnet 26 generates a strong magnetic field. Its magnetic poles and the magnetic conductor of the fixed base support beam 9 form a closed magnetic circuit, so that the fixed base 3 and the fixed base support beam 9 are attracted to each other.

[0048] First, the three sides of the box girder are welded. One of the upper or lower flanges is selected and welded to the two side webs to form a concave section. After the concave section is welded, the three sides of the internal partition 27 and the stiffening plates 11 on the three sides are welded. The remaining flange is hoisted and welded to the stiffening plate 11. Then, it is positioned and fixed to the concave section box girder by electric welding. Then, the locking support 10 is clamped onto the stiffening plate 11 inside the box girder and fixed with bolts. The fixed base support beam 9 is installed on the locking support 10. The fixed base 3 and the equipment above the fixed base 3 are lifted and placed above the fixed base support beam 9. After adjusting the position of the fixed base 3, the electromagnet 26 at the bottom of the fixed base 3 is energized and magnetized. The fixed base 3 is connected and fixed to the fixed base support beam 9. The welding robot 1 is started to weld the internal seams of the box girder.

[0049] After the welding robot 1 completes the welding of the seam within its working range, the translation drive device is activated, which drives the translation base 7 to adjust its position in the horizontal direction, and the welding robot 1 continues to weld the seam in the small space.

[0050] When it is necessary to cross the partition 27 inside the box girder, the translation base 7 moves to the middle position of the adjacent partition 27, and then the vertical turning mechanism 8 is activated to adjust the welding robot 1 to the lowest height state of the whole machine. The translation drive mechanism 6 drives the translation base 7 to move horizontally through the hole on the partition 27 and enter the next box girder section.

[0051] After the welding robot 1 completes the welding of all the welds between the extreme positions of the two ends of the translation base 7, the vertical turning mechanism 8 adjusts the welding robot 1 to the lowest height state of the whole machine, the electromagnet 26 at the bottom of the fixed base 3 is de-energized, the connection between the fixed base 3 and the fixed base support beam 9 is disconnected, and the fixed base 3 is pushed horizontally on the fixed base support beam 9 by manual means, pushing the fixed base 3 and all the equipment on it into the next work area.

[0052] The first drive motor 12 in the translation drive mechanism 6 is a servo motor equipped with a precision control system, which can realize the precise positioning and speed control of the translation base 7.

[0053] The second drive motor 17 in the vertical turning mechanism 8 is also a servo motor. Together with the precision control system, it can realize the precise posture adjustment of the welding robot 1.

[0054] Example 3

[0055] This embodiment further elaborates and supplements the implementation of the present invention based on Embodiment 1 or Embodiment 2.

[0056] The top of the fixed base 3 is provided with a sliding rail 25, and the bottom of the translation base 7 is connected to the sliding rail 25 by a slider.

[0057] Furthermore, the locking support 10 has a U-shaped structure. During installation, the U-shaped locking support 10 is secured to the stiffening plate 11. A shim is added between the locking support 10 and the stiffening plate 11 to fill the gap between them, thus accommodating the arrangement of stiffening plates 11 with different thicknesses.

[0058] The locking support 10 and the stiffening plate 11 are fixed together by bolts.

[0059] The welding robot 1 is a six-axis industrial robot. A six-axis robot can achieve multi-angle rotation, including pitch, lateral movement, and flipping, making it particularly suitable for welding seams in confined spaces.

Claims

1. An automated welding device for steel structures in tight spaces, characterized by: The system includes a welding robot (1), a fixed base (3), a translation drive mechanism (6), a translation base (7), a vertical turning mechanism (8), a fixed base support beam (9), and locking supports (10). The fixed base (3) is detachably mounted on the fixed base support beam (9). Multiple locking supports (10) are installed below the fixed base support beam (9) and are connected to the stiffening plates (11) inside the box beam through the locking supports (10). The welding robot (1) is equipped with a welding torch (2) at its front end and is mounted on a robot mounting base (4). The robot mounting base (4) is hinged to the slide (5). The slide (5) is moved and assembled on the translation base (7). The robot mounting base (4) is hinged to the translation base (7). The slide (5) moves horizontally. The vertical turning mechanism (8) performs the action of the welding robot (1) turning 90 degrees vertically around the hinge point. The translation base (7) is mounted on the fixed base (3), and the translation drive mechanism (6) drives the translation base (7) to move inside the box beam along the length direction of the fixed base (3).

2. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 1, characterized in that: The translation drive mechanism (6) includes a first drive motor (12), a first reducer (13), a first bearing seat (14), and a first drive screw (15). The first drive screw (15) is rotatably mounted on one side of the fixed base (3) through the first bearing seat (14) and connects the first reducer (13) and the first drive motor (12). A transmission component (16) is provided on the translation base (7), and the transmission component (16) is located on the same side as the first drive screw (15). The transmission component (16) is provided with a threaded hole that mates with the first drive screw (15).

3. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 1, characterized in that: The vertical turning mechanism (8) includes a second drive motor (17), a second reducer (18), a drive gear (19), a second drive screw (20), and a connecting rod (21). The two ends of the second drive screw (20) are rotatably mounted inside the translation base (7) through the second bearing seat. The bottom of the slide (5) is provided with a nut that cooperates with the second drive screw (20). The output shaft of the second drive motor (17) is connected to the input end of the second reducer (18). The drive gear (19) is fixedly mounted on the output end of the reducer. The drive gear (19) meshes with the gear of the second drive screw (20). One end of the connecting rod (21) is hinged to the robot mounting base (4), and the other end is hinged to the translation base (7).

4. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 3, characterized in that: The translation base (7) and the robot mounting base (4) are respectively provided with a first hinge ear plate (22), and a hinge hole is opened on the first hinge ear plate (22). The two ends of the connecting rod (21) are respectively provided with hinge holes, and the pin passes through the hinge holes at both ends of the first hinge ear plate (22) and the connecting rod (21).

5. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 1, characterized in that: The slide (5) is provided with a second hinge ear plate (23), and a hinge hole is opened on the second hinge ear plate (23). A side plate (24) is assembled on one side of the robot mounting base (4), and a corresponding hinge hole is opened on the side plate (24). A pin passes through the hinge hole on the second hinge ear plate (23) and the side plate (24).

6. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 1, characterized in that: The fixed base (3) is a concave beam structure. Fixed electromagnets (26) are spaced apart in the groove of the concave beam structure. When energized, they generate magnetism to connect the fixed base (3) with the fixed base support beam (9).

7. An automated welding apparatus for welding steel structures in tight spaces as claimed in claim 6 wherein: The fixed base (3) is provided with a sliding rail (25) at the top, and the bottom of the translation base (7) is connected to the sliding rail (25) by a slider.

8. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 1, characterized in that: The locking support (10) has a U-shaped structure.

9. An automated welding apparatus for welding steel structures in tight spaces as claimed in claim 8, wherein: The locking support (10) and the stiffening plate (11) are fixed together by bolts.

10. The apparatus for automated welding of steel structures in confined spaces as claimed in claim 1, characterized in that: The welding robot (1) is a six-axis industrial robot.

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