A slotting device for large-diameter steel pipe pile variable diameter section steel plate
Patent Information
- Application Number
- CN202522399046.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-12
- Publication Date
- 2026-10-09
- Estimated Expiration
- 2035-11-12
AI Technical Summary
[0005]为了解决现有用于大直径钢桩变径段钢板的开槽加工中，传统机械夹具生成效率低，产品精度不高的问题以及现有真空吸附技术中吸附力调节灵活性有限的问题，本实用新型提供一种大直径钢管桩变径段钢板用开槽装置，本实用新型解决上述问题所采用的技术方案是：一种大直径钢管桩变径段钢板用开槽装置，包括龙门铣床，吸附定位装置、工件和集成阀岛；
[0012]如上，本实用新型所提供了一种大直径钢管桩变径段钢板用开槽装置的有益效果是：本实用新型中的密封衬板中的橡胶密封圈通过自身的形变填充平台表面的微小划痕或工件底面的平整度误差形成的安装缝隙，形成可靠的密封腔，确保真空系统吸附的稳定性，密封衬板还能直接抬高了工件与真空平台的距离，为铣削组件提供了足够的避让深度，避免直接铣削组件直接切割到真空平面，集成阀岛简化了气路布局，能快速切换和精准控制真空压力，适配不同工件的加工需求，提高了设备的通用性，集成阀岛还能实时进行故障诊断与保护，降低安全事故的发生机率。
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Figure CN224824658U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of metal processing equipment, and in particular to a grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile. Background Technology
[0002] Large-diameter steel pipe piles are widely used in bridges, ports, and marine engineering. Due to their high strength, good corrosion resistance, and convenient construction characteristics, they have become a key component of foundation support structures. In practical applications, because of differences in stress requirements and soil conditions at different construction sites, it is often necessary to install a diameter-changing section on the same steel pipe pile to optimize structural stress and reduce material costs. This diameter-changing section is the transition between different diameter sections of the steel pipe pile. The slot size and positional accuracy of the steel plate in the diameter-changing section directly affect the overall structural strength and service safety of the steel pipe pile. If the slot deviation is too large, it can easily lead to stress concentration during welding of the diameter-changing section, causing cracking during later use.
[0003] Large-diameter steel pipe piles have diverse size specifications for their variable-diameter sections. Currently, the traditional clamping method for slotting the steel plates in these sections often uses mechanical clamps, such as pressure plates and bolts. However, due to the large weight of the large-diameter steel plates, using mechanical clamps is not only cumbersome and time-consuming, but also makes it difficult to guarantee the accuracy and stability of the clamping. Furthermore, during processing, the steel plates are prone to slight displacement or deformation, affecting the dimensional accuracy and surface quality of the slots, thereby reducing the overall structural performance of the steel pipe pile.
[0004] Existing vacuum adsorption devices still have many shortcomings in processing steel plates for the variable diameter sections of large-diameter steel pipe piles. On the one hand, for large-sized, irregularly shaped, or smooth-surfaced workpieces, it is difficult to achieve uniform and sufficient adsorption force, and local adsorption instability is prone to occur; they cannot well meet the high-precision and high-efficiency grooving processing requirements of steel plates for the variable diameter sections of large-diameter steel pipe piles. Utility Model Content
[0005] To address the issues of low efficiency and low product precision of traditional mechanical fixtures used in the grooving processing of steel plates for variable diameter sections of large-diameter steel piles, as well as the limited flexibility of adsorption force adjustment in existing vacuum adsorption technology, this utility model provides a grooving device for steel plates for variable diameter sections of large-diameter steel pipe piles. The technical solution adopted by this utility model to solve the above problems is: a grooving device for steel plates for variable diameter sections of large-diameter steel pipe piles, including a gantry milling machine, an adsorption positioning device, a workpiece, and an integrated valve island; The gantry milling machine includes a crossbeam, columns, a worktable, and a milling assembly. The crossbeam is fixed across the tops of the two columns, the worktable is horizontally positioned between the two columns, the integrated valve island is fixedly connected to the columns, and the milling assembly is slidably mounted on the crossbeam. The adsorption positioning device includes a vacuum platform, a sealing liner, an L-shaped reference block, a central auxiliary pin, and a positioning pin. The vacuum platform is fixedly installed on the top surface of the workbench, and a vacuum generator and a pressure sensor are connected to one side of the vacuum platform. One end of the positioning pin is connected to the vacuum platform, and the other end is connected to the sealing liner. The sealing liner is provided with through holes that correspond one-to-one with the adsorption holes. The L-shaped reference block is connected to the vacuum platform, and the central auxiliary pin vertically penetrates the central hole of the vacuum platform and the sealing liner.
[0006] The aforementioned grooving device for the steel plate of the variable diameter section of large-diameter steel pipe pile has an annular main air channel and radial branch air channels inside the vacuum platform. The annular main air channel is connected to the corresponding control interface of the integrated valve island through an independent vacuum pipeline. Multiple radial branch air channels distinguish the adsorption areas of the vacuum platform. The adsorption holes are distributed in a matrix at the end of the branch air channels. The annular main air channel serves as a negative pressure collection channel. Combined with the divergent layout of the radial branch air channels, it can evenly distribute the negative pressure generated by the vacuum generator to the matrix adsorption holes at the end of each branch. This avoids the negative pressure attenuation caused by the excessive length of the air path on the vacuum platform, ensures that the workpiece is subjected to balanced force in each area, and reduces the risk of deformation during processing.
[0007] The aforementioned grooving device for the steel plate of the variable diameter section of large-diameter steel pipe piles integrates a valve island including a reversing valve, a pressure regulating valve, and a flow regulating valve. By cooperating with pressure sensors distributed in different areas of the vacuum platform, the integrated valve island can monitor the negative pressure in each area in real time. Real-time monitoring can detect abnormal negative pressure adsorption at the first time, avoiding the problem of workpiece displacement during the cutting process due to the negative pressure in a certain area being lower than the set threshold. This reduces the scrap rate of products, the probability of tool collision damage, and the probability of workpiece falling off.
[0008] The aforementioned grooving device for the steel plate of the variable diameter section of large-diameter steel pipe piles features an integrated valve island that is a zone-controlled type. It includes vacuum control valves and pressure sensors corresponding to each adsorption zone. The vacuum control valves can independently adjust the negative pressure value of their respective adsorption zones, with an adjustment range of -0.04MPa to -0.08MPa. Pressure feedback signals from each zone are transmitted to the PLC controller via the integrated valve island's built-in bus. Zone-based negative pressure control can increase the negative pressure in areas with concentrated cutting forces, enhancing adsorption to counteract impacts, prevent workpiece displacement, and improve the equipment's processing accuracy, depending on the processing process. The bus transmission speed is much faster than distributed circuits, improving the response efficiency of the vacuum adsorption system comprised of sensors, the integrated valve island, and the PLC, thus ensuring the product's processing effect and stability.
[0009] The aforementioned grooving device for the steel plate of the variable diameter section of large-diameter steel pipe piles integrates a valve island equipped with a zoned leakage detection module. This module can independently monitor the vacuum retention rate of each adsorption zone. When the vacuum retention rate of a certain zone is lower than 90%, the PLC controller automatically closes the vacuum control valve of that zone and issues an alarm signal. Simultaneously, it increases the negative pressure value of adjacent zones for compensation, with the compensation amount being 10%-15% of the set value for that zone. This quickly locates the fault point and actively closes the vacuum control valve for that zone, preventing the continuous consumption of negative pressure in the leaking zone from causing a decrease in the adsorption force of other normal zones. This avoids the overall loosening of the workpiece due to local leakage. The compensation negative pressure in adjacent zones can fill the force gap caused by poor sealing and leakage in the edge areas, maintaining the overall fixation of the workpiece edges and preventing displacement of the workpiece during cutting due to local pressure loss. An alarm signal is issued to remind the operator to handle the situation in a timely manner, preventing workpiece detachment due to undetected leakage, which could lead to equipment collisions or personnel safety accidents.
[0010] The aforementioned grooving device for the variable diameter section steel plate of large-diameter steel pipe piles features rubber sealing rings on the contact surfaces of the sealing liner, vacuum platform, and workpiece. Positioning holes are located on the outer side of each rubber sealing ring. The sealing ring in contact with the vacuum platform blocks the connection between the platform's air passage and the external atmosphere; the sealing ring in contact with the workpiece prevents air leakage between the workpiece and the liner. Together, they form a negative pressure closed loop, ensuring that the adsorption zone maintains a stable negative pressure and provides sufficient adsorption force for the workpiece. The positioning holes only fix the position of the sealing liner and do not intrude into the sealing working area of the rubber sealing ring. This avoids damage to the sealing surface caused by direct contact between the positioning pin and the rubber sealing ring, as well as insufficient sealing area due to the positioning structure occupying the sealing space, thus preventing the application of sufficient adsorption force to the workpiece.
[0011] The aforementioned grooving device for the variable diameter section steel plate of large-diameter steel pipe piles has a top end of the central auxiliary ejector pin that is adapted to the bottom surface of the workpiece, and a servo telescopic cylinder connected to the bottom end. The servo telescopic cylinder and the vacuum generator are linked and controlled by a PLC controller. During the processing, the workpiece may be affected by its own weight or slight deformation, resulting in the edge of the workpiece being close to the sealing liner, but the center of the workpiece arching upward. The ejector pin pushes upward from inside the platform, just hitting the suspended point of the center of the workpiece, eliminating the suspended gap of the workpiece. At this time, the entire bottom surface of the workpiece is in seamless contact with the sealing liner. The vacuum system will not leak air when drawing a vacuum and can stably form a negative pressure. During the processing, the cutting force of the milling component may cause the center of the workpiece to sink downward, resulting in a deeper cutting depth or vibration. After the central auxiliary ejector pin pushes upward, it adds a rigid support point to the center of the workpiece.
[0012] As described above, the beneficial effects of the grooving device for the variable diameter section of large-diameter steel pipe pile provided by this utility model are as follows: The rubber sealing ring in the sealing liner of this utility model fills the installation gaps formed by the tiny scratches on the surface of the platform or the flatness error of the bottom surface of the workpiece through its own deformation, forming a reliable sealing cavity, ensuring the stability of the vacuum system adsorption. The sealing liner can also directly raise the distance between the workpiece and the vacuum platform, providing sufficient avoidance depth for the milling components, avoiding direct cutting of the milling components to the vacuum plane. The integrated valve island simplifies the gas path layout, can quickly switch and accurately control the vacuum pressure, adapt to the processing needs of different workpieces, improve the versatility of the equipment, and can also perform real-time fault diagnosis and protection, reducing the probability of safety accidents. Attached Figure Description
[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0014] Figure 1 This is a schematic diagram of the overall design of this utility model; Figure 2 This is a partial sectional view of the present invention; Figure 3 This is an exploded view of the present invention; Figure 4 for Figure 1 A magnified view of a section at point I; Figure 5 for Figure 2 A magnified view of section II.
[0015] Summary of figure labels and their descriptions: 1. Gantry milling machine; 11. Crossbeam; 12. Column; 13. Worktable; 14. Milling assembly; 2. Adsorption positioning device; 21. Vacuum platform; 211. Adsorption hole; 212. Annular main air passage; 213. Branch air passage; 22. Sealing liner; 221. Through hole; 222. Rubber sealing ring; 223. Positioning hole; 23. L-shaped reference stop; 24. Central auxiliary ejector pin; 25. Positioning pin; 3. Workpiece; 4. Integrated valve island. Detailed Implementation
[0016] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.
[0017] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. When a component is said to be "set on" another component, it can be directly set on the other component or there may be an intervening component.
[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.
[0019] Please see Figure 1 A grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile includes a gantry milling machine 1, an adsorption positioning device 2, a workpiece 3, and an integrated valve island 4; the gantry milling machine 1 includes a crossbeam 11, columns 12, a worktable 13, and a milling assembly 14. The crossbeam 11 is fixed across the top of the two columns 12, the worktable 13 is horizontally arranged between the two columns 12, the integrated valve island 4 is fixedly connected to the columns 12, and the milling assembly 14 is slidably mounted on the crossbeam 11. The adsorption positioning device 2 includes a vacuum platform 21, a sealing liner 22, an L-shaped reference block 23, a central auxiliary pin 24, and a positioning pin 25. The vacuum platform 21 is fixedly installed on the top surface of the workbench 13, and a vacuum generator and a pressure sensor are connected to one side of the vacuum platform 21. One end of the positioning pin 25 is connected to the vacuum platform 21, and the other end is connected to the sealing liner 22. The sealing liner 22 is provided with through holes 221 that correspond one-to-one with the adsorption holes 211. The L-shaped reference block 23 is connected to the vacuum platform 21, and the central auxiliary pin 24 vertically penetrates the central hole of the vacuum platform 21 and the sealing liner 22.
[0020] Please see Figure 5The vacuum platform 21 is equipped with an annular main air channel 212 and radial branch air channels 213. The annular main air channel 212 is connected to the corresponding control interface of the integrated valve island 4 through an independent vacuum pipeline. Multiple radial branch air channels 213 distinguish the adsorption areas of the vacuum platform 21. The adsorption holes 211 are distributed in a matrix at the end of the branch air channels 213. The annular main air channel 212 serves as a negative pressure collection channel. With the divergent layout of the radial branch air channels 213, the negative pressure generated by the vacuum generator can be evenly distributed to the matrix adsorption holes 211 at the end of each branch. This avoids the negative pressure attenuation caused by the excessive length of the air path in the vacuum platform 21, ensuring that the workpiece 3 is subjected to balanced force in each area and reducing the risk of deformation during processing.
[0021] Please see Figure 1 and Figure 2 The integrated valve island 4 includes a reversing valve, a pressure regulating valve, and a flow regulating valve. By working with pressure sensors distributed in different areas of the vacuum platform 21, the integrated valve island 4 can monitor the negative pressure in each area in real time. Real-time monitoring can detect abnormal negative pressure adsorption at the first time, avoiding the problem of workpiece 3 displacement during the cutting process due to the negative pressure in a certain area being lower than the set threshold. This reduces the scrap rate of the product, the probability of tool collision damage, and the probability of workpiece 3 falling off.
[0022] Please see Figure 2 The integrated valve island 4 is a zone-controlled valve island, containing vacuum control valves and pressure sensors corresponding to each adsorption zone. The vacuum control valves can independently adjust the negative pressure value of the corresponding adsorption zone, with an adjustment range of -0.04MPa to -0.08MPa. The pressure feedback signals of each zone are transmitted to the PLC controller through the built-in bus of the integrated valve island 4. The zoned negative pressure control can increase the negative pressure in the area where the cutting force is concentrated according to different processing processes, enhance the adsorption force to resist impact, prevent the workpiece 3 from shifting, and improve the processing accuracy of the equipment. The bus transmission speed is much faster than the distributed circuit, which improves the response efficiency of the vacuum adsorption system consisting of sensors, integrated valve island 4, and PLC, ensuring the processing effect and stability of the product.
[0023] Please see Figure 3The integrated valve island 4 is equipped with a zoned leakage detection module, which can independently monitor the vacuum retention rate of each adsorption zone. When the vacuum retention rate of a certain zone is lower than 90%, the PLC controller automatically closes the vacuum control valve of that zone and issues an alarm signal. At the same time, it increases the negative pressure value of the adjacent zone for compensation. The compensation amount is 10%-15% of the set value of that zone. This quickly locates the fault point and actively closes the vacuum control valve of the corresponding zone, preventing the continuous consumption of negative pressure in the leaking zone from causing the adsorption force of other normal zones to decrease. This can prevent the overall workpiece 3 from loosening due to local leakage. The compensation negative pressure of the adjacent zone can fill the force gap caused by poor sealing and leakage in its edge area, maintaining the overall fixation of the edge of the workpiece 3 and preventing the workpiece 3 from shifting during the cutting process due to local pressure loss. An alarm signal is issued to remind the operator to deal with it in time, and to prevent the workpiece 3 from falling off due to undetected leakage, which could cause equipment collisions or personnel safety accidents.
[0024] Please see Figure 3 and Figure 5 Rubber sealing rings 222 are provided on the contact surfaces of the sealing liner 22, the vacuum platform 21, and the workpiece 3. Positioning holes 223 are provided on the outer side of the rubber sealing rings 222. The sealing rings 222 in contact with the vacuum platform 21 can block the communication between the platform air passage and the external atmosphere; the sealing rings 222 in contact with the workpiece 3 can block the air leakage between the workpiece 3 and the liner. Together, they form a negative pressure closed loop to ensure that the adsorption area can maintain a stable negative pressure and provide sufficient adsorption force for the workpiece 3. The positioning holes 223 are only responsible for fixing the position of the sealing liner 22 and do not invade the sealing working area of the rubber sealing rings 222. This avoids damage to the sealing surface caused by direct contact between the positioning pins 25 and the rubber sealing rings 222, as well as insufficient sealing area caused by the positioning structure occupying the sealing space, which would prevent the workpiece 3 from being unable to provide sufficient adsorption force.
[0025] Please see Figure 4 The top of the central auxiliary ejector pin 24 is equipped with a top head that fits the bottom surface of the workpiece 3, and the bottom end is connected to a servo telescopic cylinder. The servo telescopic cylinder and the vacuum generator are linked and controlled by a PLC controller. During the processing, the workpiece 3 may be affected by its own weight or slight deformation, and the edge of the workpiece 3 may be close to the sealing liner 22, but the center of the workpiece 3 may be arched upward. The ejector pin 24 pushes upward from inside the platform, just hitting the suspended point of the center of the workpiece 3, eliminating the suspended gap of the workpiece 3. At this time, the entire bottom surface of the workpiece 3 is in seamless contact with the sealing liner 22. The vacuum system will not leak air when drawing a vacuum and can stably form a negative pressure. During the processing, the cutting force of the milling component 14 may cause the center of the workpiece 3 to sink downward, resulting in a deeper cutting depth or vibration. After the central auxiliary ejector pin 24 pushes upward, it adds a rigid support point to the center of the workpiece 3.
[0026] A specific application of this embodiment is as follows: With the suction force of the vacuum platform 21 cut off, the sealing liner 22 is initially positioned by installing it in the corresponding position on the vacuum platform 21 using the positioning pin 25. Then, an L-shaped reference block 23 adapted to the workpiece 3 is installed on the vacuum platform 21. During installation, the horizontality of the L-shaped reference block 23 must be ensured, and the working surfaces of the two L-shaped reference blocks 23 are positioned with the x-axis and y-axis of the vacuum platform 21 as the positioning references, respectively. At this time, the workpiece 3 can be placed on the sealing liner 22, and both sides of the workpiece 3 need to contact the working surfaces of the two L-shaped reference blocks 23, respectively. This completes the limiting and positioning of the workpiece 3. The vacuum platform 21 and the central auxiliary ejector pin 24 are then started synchronously. The vacuum platform 21 suctions the workpiece 3, and the central auxiliary ejector pin 24 extends and presses against the bottom surface of the workpiece 3. This completes the clamping of the workpiece 3, and the gantry milling machine 1 is started to perform grooving processing on the workpiece 3.
[0027] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application and are not intended to limit it. Although this application has been described in detail with reference to the embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this application without departing from the spirit and scope of the technical solutions of this application.
Claims
1. A grooving device for the steel plate of a large-diameter steel pipe pile with variable diameter section, comprising a gantry milling machine (1), an adsorption positioning device (2), a workpiece (3), and an integrated valve island (4), characterized in that: The gantry milling machine (1) includes a crossbeam (11), columns (12), a worktable (13) and a milling assembly (14). The crossbeam (11) is fixed across the top of the two columns (12). The worktable (13) is horizontally arranged between the two columns (12). The integrated valve island (4) is fixedly connected to the column (12). The milling assembly (14) is slidably mounted on the crossbeam (11). The adsorption positioning device (2) includes a vacuum platform (21), a sealing liner (22), an L-shaped reference block (23), a central auxiliary pin (24), and a positioning pin (25). The vacuum platform (21) is fixedly installed on the top surface of the workbench (13), and a vacuum generator and a pressure sensor are connected to one side of the vacuum platform (21). One end of the positioning pin (25) is connected to the vacuum platform (21), and the other end is connected to the sealing liner (22). The sealing liner (22) is provided with through holes (221) that correspond one-to-one with the adsorption holes (211). The L-shaped reference block (23) is connected to the vacuum platform (21), and the central auxiliary pin (24) vertically penetrates the central hole of the vacuum platform (21) and the sealing liner (22).
2. The grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile according to claim 1, characterized in that: The vacuum platform (21) is provided with an annular main air channel (212) and radial branch air channels (213). The annular main air channel (212) is connected to the corresponding control interface of the integrated valve island (4) through an independent vacuum pipeline. Multiple radial branch air channels (213) distinguish the adsorption area of the vacuum platform (21). The adsorption holes (211) are distributed in a matrix at the end of the branch air channels (213).
3. The grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile according to claim 2, characterized in that: The integrated valve island (4) includes a reversing valve, a pressure regulating valve and a flow regulating valve. The integrated valve island (4) works in conjunction with pressure sensors distributed in different areas of the vacuum platform (21) to monitor the negative pressure in each area in real time.
4. The grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile according to claim 3, characterized in that: The integrated valve island (4) is a zone-controlled valve island, which includes a vacuum control valve and a pressure sensor corresponding to each adsorption zone. The vacuum control valve can independently adjust the negative pressure value of the corresponding adsorption zone, with an adjustment range of -0.04MPa to -0.08MPa. The pressure feedback signal of each zone is transmitted to the PLC controller through the built-in bus of the integrated valve island (4).
5. The grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile according to claim 4, characterized in that: The integrated valve island (4) is equipped with a zone leakage detection module, which can independently monitor the vacuum retention rate of each adsorption zone. When the vacuum retention rate of a certain zone is lower than 90%, the PLC controller automatically closes the vacuum control valve of that zone and sends an alarm signal. At the same time, it increases the negative pressure value of the adjacent zone for compensation. The compensation amount is 10%-15% of the set value of that zone.
6. The grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile according to claim 1, characterized in that: The sealing liner (22) is provided with rubber sealing rings (222) on the contact surfaces with the vacuum platform (21) and the workpiece (3), and positioning holes (223) are provided on the outer side of the rubber sealing rings.
7. The grooving device for the steel plate of the variable diameter section of a large-diameter steel pipe pile according to claim 1, characterized in that: The top of the central auxiliary ejector pin (24) is provided with a top head (241) that is adapted to the bottom surface of the workpiece (3), and the bottom is connected to a servo telescopic cylinder. The servo telescopic cylinder and the vacuum generator are controlled in conjunction with each other by a PLC controller.