JPH0237277B2 - IGATAHARINOSEISAKUHOHO - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an I-shaped beam made of steel through a series of steps such as assembly, welding, turning the sides inside out, chamfering, drilling, and assembling.

Structures such as steel frames of buildings and bridges, such as beams,
Usually, as shown in Fig. 1, the web 1 and the flange 2 have an I-shaped cross section, and the web 1 has a hole 3 for passing an electric wire or tube through or a light hole, and a stiffener 4 is installed between them. There are many structures that can be used. or,
Both ends are drilled with holes 5 for bolts or bets for connection with brackets provided on columns or other beams, etc., and welding grooves 6 are machined on the end faces, or welding grooves 6 are processed in place of the welding grooves 6. A bolt hole is provided. Many beams having the same shape are used for a single building, bridge, etc.

By the way, the conventional process for manufacturing beams is to lay out several to ten or more flanges flat and line them up, mark the installation positions of the webs, collect them and transport them using a crane.
Weld grooves are removed at both ends by gas cutting, or holes are made with a drill, etc., and the pieces are collected again using a crane and transported. In the same way, spread several webs of the structure flat and cut out light holes, stiffeners,
Bolt holes and the like are marked, collected and transported by a crane, and then spread out and holes are drilled at the pre-marked positions. The flange and web plates processed in this way were brought in using a crane.
After assembling the shape and tacking, continuous welding is carried out.
Complete the assembly. Next, after I is assembled, welding distortion at the neck weld of the flange is removed by cold pressing or linear heating. After that, stiffeners, brackets, etc. are attached to the main material of the I-group and welded to complete the manufacture of the beam.

As mentioned above, in the conventional beam manufacturing method, the parts are spread out one by one using a crane and processed in one process, and once this is completed, the parts are collected and transported to the next process by crane, and then spread out again and processed in the next process. Because the manufacturing process involved repeating the process of processing, the parts had to be handled extremely often using cranes, which required many workers and increased working time.
The disadvantage was that work efficiency was poor, and as wage rates rose, manufacturing costs rose proportionately. In addition, since welding between the web and the flange was performed by fixing the workpiece and moving the welding machine, a guide was installed to ensure accurate movement of the welding machine, and we also installed a guide to prevent long cables, hoses, etc. from becoming loose. This not only makes the equipment bulky and takes up space, but also requires returning the welding machine to the initial position each time one side of a beam is welded, which reduces efficiency. It also had some drawbacks that made it worse.

In view of the above-mentioned drawbacks of conventional manufacturing methods for structures such as steel frames and beams such as bridges, this invention reduces the number of times a workpiece is handled by a crane, which in turn makes it possible to significantly reduce the number of workers and work time. Another object of the present invention is to provide a method for manufacturing an I-shaped beam that eliminates problems associated with movement of a welding machine during welding.

To manufacture an I-shaped beam, the workpiece is transferred between each process on the production line in the longitudinal direction of the workpiece using a conveyor, and the manufacturing process involves forming a web and flange that have been externally machined into the required dimensions and shape into an I-shaped beam. Assembly process to assemble into shape, welding process between one side of the web and the flange,
It consists of a front-back reversal process, a welding process for welding the other side of the web to the flange, and a chamfering process for developing the flange tip welding and a process for drilling holes in the web.In the above assembly process, the web surface is leveled. Then, the flange surfaces are held vertically on a conveyor while maintaining relative positions, and both outer sides of the flange are pressed and clamped by a fixed roller and a roller whose position can be adjusted via a hydraulic cylinder, and the fixed rollers are brought into contact with each other. Assembling is performed so that the gap between the members is minimized based on the surface, and in each of the above-mentioned front and back welding processes, the workpiece is welded by a fixed roller and a roller whose position can be adjusted via a hydraulic cylinder. Both outside sides of the flange are clamped, and the web is clamped and conveyed by a conveyor roller and a driven roller whose vertical position can be adjusted by a hydraulic cylinder. At the same time, the back side of the welded part of the flange is welded at a fixed position. The workpiece is heated with an amount of heat that is approximately equal to the amount of heat input during welding, and in the above-mentioned face-up process, the workpiece is carried into the cylinder with the web held between a pair of rollers provided in the rotating cylinder, and The outer surface of the flange is held between a roller fixed to the rotary cylinder and a roller facing the roller whose position relative to the inner surface of the rotating cylinder can be adjusted via a hydraulic cylinder, and after being reversed together with the rotating cylinder, it is transported out of the cylinder. There is.

Hereinafter, the present invention will be explained in detail based on drawings showing embodiments thereof.

FIG. 2 shows an outline of one embodiment of a beam manufacturing line based on the present invention, together with a manufacturing process diagram showing the process steps in correspondence with the equipment that performs each process.

The beam manufacturing line of this embodiment is as shown in the figure.
Shape assembly machine 10, surface welding machine 20, front/back reversal device 3
0, a back welding machine 40, a chamfering hole drilling device 50, and a large assembly place 60 are arranged in this order on a series of beam manufacturing lines. The workpiece is transferred between the equipment for each process by a roller conveyor 7, which supports the web of the workpiece with rollers and moves it in the longitudinal direction of the workpiece. A monorail hoist 8 is provided above the workpieces for which large assembly on one side has been completed, and then the workpieces are inverted and large assembly is performed on the other side, and the completed beams are loaded onto pallets 80 for transport. For reversing the workpiece, a reversing device 9, such as a hanging type or a ground-mounted type, is attached to the hoist.

The equipment that performs each of the above steps is installed on a series of beam manufacturing lines, but due to space constraints, the diagram shows the parts up to large assembly on one side and the parts after reversal. . From assembly to single-sided assembly, the workpieces are conveyed in the longitudinal direction of the beam with the web 1 supported by the rollers of the roller conveyor with the beam lying on its side, so that the workpieces are arranged in a straight line. From this point forward, it is not necessarily necessary to arrange them on the same straight line. The stiffeners, joints, brackets, etc. to be attached to the beams can be arranged and manufactured in line according to their structure and welding method.

Below, the outline of each piece of equipment in this manufacturing line and the method for manufacturing beams using these equipment will be explained.

First, the web 1 and the upper and lower flanges 2 are put into the assembly machine 10 with the beams laid down by an overhead crane or a dedicated loading device (not shown). The assembly machine 10 is constructed as shown schematically in FIG. 2 and in cross section in FIG. 3, and the web 1 is placed horizontally on a roller conveyor 7 rotatable around a horizontal axis. On the other hand, the flange 2 is placed on a roller (not shown) that is independent of the roller conveyor 7, and is rotated around a vertical axis so that the outer surface thereof is aligned with a predetermined reference position, facing the outer surface of one of the flanges. A plurality of rollers 11 are provided. A vertical roller 13 whose position is laterally adjustable by a hydraulic cylinder 12 is provided opposite the outer surface of the other flange. Therefore, the web 1 and the flanges 2 can be moved independently in the longitudinal direction, and after accurately aligning the front and rear ends, the flanges 2 on both sides are pressed by the hydraulic cylinder 12 with the rollers 11 and 13. As a result, the workpiece is automatically positioned at the reference position. After positioning, the web 1 and flange 2 are temporarily attached. The beam, which has been tacked, is freed by retracting the hydraulic cylinder 12 and moved on the roller conveyor 7 towards the surface welding machine 20. If the weight of the beam is light, it can be easily moved by pushing it on the roller conveyor 7, but
When the weight of the beam exceeds a certain level, a roller conveyor is driven by a motor or the like. Assembly machine 10 and welding machine 20
A roller conveyor 7 is provided between the welding machine 20 and the welding machine 20, and the workpiece is conveyed until the leading end of the workpiece is gripped by a transfer means in the welding machine 20.

The surface welding machine 20 has an external appearance shown in FIG. 2 and a cross section shown in FIG. roller 22
A roller conveyor 22 consisting of a pair of rollers b is provided. Between this pair of rollers, rollers 24 that rotate around vertical axes are provided facing the outer surfaces of both sides of the beam holding the web 1, and the outer surface of one roller is positioned at the reference conveyance position of the beam. match,
The position of the other roller can be adjusted in the lateral direction by a hydraulic cylinder 25. Therefore, the workpiece is conveyed at a predetermined constant speed while accurately maintaining its vertical and horizontal positions by the roller conveyor 22 and rollers 24 described above. Welding torch 2 with the tip facing the corner with flanges 2 on both sides of the upper surface of web 1
6 are set immovably relative to the earth on both sides.
Of course, the torch angle and its corner position can be adjusted depending on the welding conditions. Therefore, continuous welding is performed by moving the workpiece at a constant speed. The back side (i.e. outside) of the welding point of flange 2
Strain relief gas torches 27 are installed on both sides so that the tip of the flame hits the same position as the welding point or a position slightly shifted forward, and heats the back side of the welding position with an amount of heat that is approximately equal to the heat input from welding. By doing this, welding distortion is removed. welding torch 2
A slag removal device (not shown) is provided in front of the welding device 6 to continuously remove slag that is formed on the surface of the welding speed. A suitable slag removal device is a device in which a number of wires are attached to the tip of an air gun with the tips facing the peed surface, and the tips of the wires bend to remove the slag. The operating positions of the welding machine torch 26, strain relief male torch 27, and slag removal device are slightly shifted in this order, but after moving the tip of the workpiece to the welding point, press one switch on the welding machine. As a result, first, the welding arc is automatically ignited, the strain relief gas torch 27 is ignited after a predetermined time lag by the timer, and then the slag removal device is activated. When welding on one side of a single beam is completed and a limit switch (not shown) is activated by a protrusion provided at the tip of the workpiece or at an appropriate position, the power to the welding machine is first turned off, and the timer determines the above-mentioned timing. At the same timing, the actions of the strain relief gas torch 27 and the slag removal device are sequentially stopped. Note that the welding wire supply device 28 is connected to the welding machine 2.
It is provided on the top plate of the casing 29 of 0. Since a large amount of welding wire is consumed during line operation, a large dedicated coil 28' is installed near the welding machine 20.
It is optimal if .

The workpieces coming out of the surface welding machine 20 are sequentially inserted into the reversing device 30 from the beginning. Reversing device 3
0, as shown in FIG. 2 and the cross section in FIG. Roller conveyor 3
A plurality of sets of 3 are provided, and 1 is provided on the outside of both flanges.
A plurality of sets of rollers 35 equipped with hydraulic cylinders 34 are provided on one side of the workpiece, which receives the workpiece discharged from the surface welding machine 20, accurately holds the workpiece in the vertical and horizontal directions using these rollers, and transports it forward. When both ends of the welding machine come to a position where they do not touch either the front or rear welding machines 20, 40, the limit switch stops the welding machine.
When the turning roll 31 is turned on in this state, the rotating cylinder 32 is moved to the inner roller conveyor 3.
3. It rotates together with the roller 35 and the workpiece held by these, and when it rotates accurately 180 degrees, the limit switch is activated and the turning roll 31
The power to the drive motor is cut off and rotation stops. As a result, it rotates exactly 180 degrees around its central axis and flips inside out. The inverted workpiece is conveyed toward the back welding device 40 by the roller conveyor 33 in the inverting device 30.

The configuration and operation of the back welding machine 40 are exactly the same as the front welding machine 20, and performs fillet welding on both sides of the back side of the web of the workpiece coming out of the reversing device 30, and then welds the welds on the roller conveyor 7. Drain to the top.

As described above, the beam after fillet welding on both sides of the web 1 and the flange 2 is completed by the chamfering hole drilling device 5.
0 by the roller conveyor 7. Flange development automatic chamfering device 5 is placed at positions corresponding to the tips of the flanges at the four corners of the beam set at the predetermined positions.
1 is provided. When this automatic chamfering device is turned on, it automatically performs gas cutting from the upper end of the flange groove downwards, and when it reaches the lower end, the gas is cut off by the action of the limit switch, and the torch automatically returns to its original position. to return to normal. Also, web 1
One or more automatic small circle cutting devices 52 are provided for cutting out holes 3 such as light holes, etc.
This gas cutting torch also ignites by turning on the switch, and automatically cuts over a circumference of a predetermined radius.
It is designed to automatically stop operating when a 360° cut is made. Therefore, when one operator turns on the switches of each of the above-mentioned cutting devices in sequence, the respective cutting devices are operated in sequence, and chamfering and drilling are automatically performed. The workpiece that has undergone gas cutting is moved by the roller conveyor 7 so that the perforated part at one end is directly under the multi-axis drill 53 provided at the front of the chamfering hole drilling device, and multiple holes are simultaneously drilled by the drill. Ru. Since the drilling speed of the drill is fast, the required number of holes may be drilled by moving a single drill. When the drilling at one end of the workpiece is completed, the workpiece is transported so that the other end is placed under the multi-spindle drill 53, and drilling is performed. Similarly, when drilling holes in flanges, a horizontal drill is installed on the main line.

The workpiece with the chamfered holes completed is brought to the assembly position 60 by the roller conveyor 7, and the stiffener 4 is welded to one side of the web 1.

In order to weld the stiffener to the opposite side, it is necessary to turn the workpiece over, but since the stiffener has already been welded and holes have been made on one side of the web 1, it is necessary to weld the stiffener to the opposite side. A method in which both sides are held between a pair of rollers cannot be adopted. Therefore,
A monorail hoist 8 is provided for handling the workpiece for further processing, and for reversing it is fitted with a reversing device, for example of a lifting type or of a ground-mounted type.

The workpiece thus turned over is transported by the hoist 8 to the next large assembly position 70, where the web 1
A stiffener is attached and welded to the back side of the beam, and the thus completed beam is again loaded onto a pallet 80 by the hoist 8 and carried out.

Incidentally, it is also possible to carry out the large assembly of the back side on a trolley and transport it to the pallet 80 by the trolley.

As is clear from the above description, in the method of the present invention, the crane is used when inserting the web and flange plates into the assembly device 10, when reversing after one-sided large assembly, and when loading the manufactured beam onto the pallet 80. The number of times the crane is used is significantly reduced compared to the conventional method, which uses a crane to collect parts in each process, transports them to the next process, spreads them flat, and processes them repeatedly. By using a conveyor, especially an easy-to-handle roller conveyor, as a conveyance means, it is possible to significantly reduce the number of workers and working time.

Moreover, this production line only needs to be about 100 meters long when manufacturing a beam with a length of about 6 meters, for example.

In addition, only the assembly, surface welding, inversion, and single-sided welding processes, which have a remarkable work time saving effect compared to conventional methods, are placed on the production line using conveyor transport, and the other processes are the same as conventional processing methods. Considerable effects can also be expected if this is adopted. On the contrary, the second
If a painting process is further added to the production line of the embodiment shown in the figure, it will become even more complete.

The embodiments in which the present invention is applied to the manufacture of beams have been described above, but the present invention can also be applied to the manufacture of other structures such as columns.

As described above, according to the present invention, when manufacturing structures such as steel beams, the number of times a crane is used is significantly reduced, which greatly reduces the required labor time. By moving the parts to perform welding, the equipment becomes simpler and efficiency improves, and even if the equipment is expensive, the reduction in labor costs and the improvement in work efficiency more than compensate for the cost. A remarkable effect can be obtained on down.

[Brief explanation of drawings]

Figure 1 is a perspective view showing one example of a typical beam, Figure 2
The figure is a perspective view and a process diagram showing the arrangement of a beam manufacturing line according to an embodiment of the present invention, and FIGS. 3, 4, and 5 are sectional views taken along lines -, -, and - in FIG. 2, respectively. It is. 1...web, 2...flange, 3...hole, 4
... Stiffener, 6 ... Welding groove, 7 ... Roller conveyor, 10 ... Assembly machine, 20, 40 ... Welding machine, 30 ... Reversing device, 50 ... Chamfering and drilling device, 60, 70 ... ...large group position.

Claims (1)

[Claims] 1 Manufacturing of an I-shaped beam with an I-shaped cross-section, which is made by welding a web made of a steel plate and a flange, in which the workpiece is transferred between each process on a production line in the longitudinal direction of the workpiece using a conveyor. In this method, the manufacturing process includes an assembly process of assembling the web and flange that have been externally processed to the required dimensions and shape into a mold shape, a welding process of welding one side of the web to the flange, a process of turning the other side of the web to the flange, and a process of assembling the flange and the other side of the web. It consists of a welding process, a process of chamfering the welding groove at the tip of the flange, and drilling a hole in the web in this order, and in the above assembly process, the relative position is adjusted so that the web surface is horizontal and the flange surface is vertically positioned. The flange is held on a conveyor, and both outer sides of the flange are pressed and clamped by a fixed roller and a roller whose position can be adjusted via a hydraulic cylinder, so that the gap between the members is minimized based on the contact surface of the fixed roller. In each of the above-mentioned front and back welding processes, the workpiece is held on both outside sides of the flange by a fixed roller and a roller whose position can be adjusted via a hydraulic cylinder, and a conveyor roller and a hydraulic cylinder. The web is held and conveyed by a driven roller whose vertical position can be adjusted and is welded at a fixed position, and at the same time, the back side of the welded part of the flange is heated with an amount of heat that is approximately equal to the amount of heat input during welding. In the above-mentioned front-back reversing process, the workpiece is conveyed into the cylinder with the web held between a pair of rollers provided in the rotating cylinder, and facing a roller fixed to the inner surface of the rotating cylinder, which is then heated by hydraulic pressure. A method for manufacturing an I-shaped beam, characterized in that the outer surface of the flange is held between rollers whose position can be adjusted relative to the inner surface of the rotating cylinder via a cylinder, the flange is inverted together with the rotating cylinder, and then the I-shaped beam is carried out of the cylinder.