Design and calculation of welding positioning mode for cross beam*

Jing－yun ZHAO，Xue－li CHENG

Henan Mechanical and Electrical Engineering College，Xinxiang 453002，China

Design and calculation of welding positioning mode for cross beam*

Jing－yun ZHAO?，Xue－li CHENG

Henan Mechanical and Electrical Engineering College，Xinxiang 453002，China

In this paper，based the processingmethod of cross beam used in steelstructure factory building as the research object，because the cross beam w ithout special p rofiles，so we need two profiles spell-we lding.The ordinary submerged arc welding equipm ent cannot normal app lied welding，and manualspell-welding cannot guarantee the quality，due to structural constraints.In order to ensure accuracy of cross beam welding，before the design of specialwelding machine，the error calculation was conducted in view of positioning method of special welding machine，and find out the reasonable positioning mode，provide theoretical support formanufacturing specialwelding m achine.

Cross beam，Spell-welded，Positioning

*Project supported by the Henan Provincial to Youth Backbone Teachers in Colleges and Universities:Research on Crane U－shaped Girder Integral Molding Process(No.2012GGJS －206)

? Jing－yun ZHAO， Associate professor. E－mail:hncad@163.com

1.Introduction

In 2001，SETC(the state economic and trade commission)approved the light steel structure residential buildings as the breakthrough point of the steel，and officially listed as national key innovation technology，steel structure factory building can shorten the construction period，especially in metallurgy，electric power，heavy machinery plant，etc.the larger span steel support is needed，at the same time some special venues，in order to highlight the industrial beauty，requires structural design reflects the architectural features，such as the Beijing Olympic Games main stadium is the use of steel structure house，and most of the venues of the ShanghaiWorld Expo is builtwith steel structure.Chinese steel production reached 8.8 tons，which also provides the material basis for further application of steel structure building.

Although from the outside，steel structure workshop coordinated，but due to the different nature of the various production companies，types of plant layout are different，and therefore it requiresmore types of steel components to complete the assembly workshop.In the construction of steel structure the beam is an important bearing components，mainly subjected to bending and distortion moment，if divided by function，the type of beam is divided into floor beams，crane beam，tower beams，according to the classified section of the beam，the beam is divided into type steel beams and composite beam，section type is commonly used steel structure component of the beam，as is shown in Figure1.

2.Application and positioning mode of the cross-beam

Cross－beam steel structure factory building is a common building component，which belongs to a combination of cross－section beam.Cross－beam is used as the column of steel structure，and four sides can made a four－way connection structure，as shown in Figure 2.Plant of different structure，different stress conditions，cross－sectional dimensions of the cross－beam，are from 100 mm to 800 mm.Crossbeam yield little，do not belong to the national standard profiles.Production companies are to buy steel，will be one of the beams from the intermediatemesh，to obtain two T steel，welding with the addition of a steel composite.The current standard 工－beam section size heightminimum size is 100 mm，themaximum height of 630 mm，therefore the minimum and maximum height of the cross beam are respectively 100 mm，and 630 mm，if the cross－sectional dimension exceeds630 mm，is the use ofmultiple pieces of steel plate after cutting welding.

Figure 1.Cross section form of the common steel structure beam

Figure 2.The connection sketch of cross beam

Submerged arc welding only can be flat，T－shaped steel fillet weld easy to collapse，to ensure weld penetration neat appearance but also welding，must adopt ship welding，in order to facilitate welding，before welding machine，cross beam need rotated 45 degrees through indexingmachine，making fillet weld symmetrical upward.Because of the crossbeam component longer needs a total of four seam welding，using specialwelding fixture fixed position.

According to the structural requirements，submerged arc welding trolley moving guide can only be set on the outside of the cross－beams，cross－sectional dimensions of steel structure is large，the cantilever is too long，poor stability.And with the guide translation，the accumulated error due submerged arc welding trolley guide rail and the cross beam are not parallelwill producemore and more，and even affect the welding seam offset.Design ideas of special welding machine is position from the internal cross beam，eliminate displacement error of the welding dolly in moving process.

Internal positioning mainly consider the following three waysrespectively，is through the use of unilateral localization of T slots，using the cross outer edge positioning and using cross Inner edge localization，as shown in Figures 3～5.

Figure 3.Unilateral positioning welding

Figure 4.Cross outer edge positioning welding

Figure 5.Cross inner edge positioning welding

Using T－slot edge location，the main advantage of the T－slot of the upper edge and the edge as a po－sitioning surface，the lower edge of an elastic auxiliary support is not disengaged from the positioning surface.This positioning method has the advantages of simple structure，themain problems are:the support of the cantilever tip is too long，themove will generate vibrations，thus affecting the arcing effect.Unilateral positioning accuracy depends on the installation manufacturing errors of T plate，installation and manufacturing errors on the great influence of weld positioning precision.Ship welding，conductive tip relative to the weld pair requirements very strict，to take unilateral positioning can not guarantee pair.So whether it is inside or outside the edge，as long as long while using be considered as the V－grooves，by means of V－grooves on the neutral can easily achieve positioning［1］.Figure 4 shows the cross outer edge location，and Figure 5 shows the cross inner edge location，in what form the specific needs further calculations.

3.Calculation of positioning error

The errors aremainly due to three factors using both sides of the cross－beam positioning，the first is caused bymanufacturing errorδDof the both sides of positioning surface and a conductive tip installation location;second is caused by angle deflectionδathat T－shaped steel welding position is not accurate，third is caused by surface irregularities Φ of T－shaped steel，as shown in Figure 6，the following were calculated，in order tomake qualitative analysis，calculated by 40b mode 工－shaped steel，themain parameters of40B for height h=400，width b=144，thickness d=12.5，feet thick t=16.5.

3.1.Positioning error caused by locating surface and welding position machining errorsδD

For the convenience of calculation，the two positioning point of tangency，two locating surface is tangent to a circle，the radius of the circle is simplified as distance of a conductive tip and positioning surface.Themanufacturing error of the circle size is positioning error caused by themachining distance error［2］.As can be seen from Figure 6(a)，distance of O1O2can be regarded as the positioning error:

According to the Handbook of mechanical design，welding connection device manufactured using IT7 level accuracy，using the outer edge of the positioning，the basic size of 250 mm，positioning error is 0.052 mm，the positioning using an inner edge，the basic dimensions of120mm，the positioning error of 0.040 mm.

3.2.Positioning error caused by T-beam angle inaccurateδa

The theory position of T－shaped steel and H－shaped steel should be straight，but the actual clamping and 工－shaped steel rolling processmay produce angular errors，from Figure 6(a)O1O3distance can be regarded as the positioning error.δa=a －90°

According to the Ministry ofMetallurgical Industry recommended standard YB(T)56 －87 1.1.2.4 requirements，the slope of the outer leg(leg)shall not bemore than 0.015b.The δa=arctg(0.015b/b)=artg0.015=0.34.

3.3.Positioning error caused by the surface irregularities of T-shaped steel

Φ for flatness error，O1O4distance can be regarded as the positioning error as shown in Figure 6(b)，leg thickness tolerance of 工－shaped steel is 0.012t(t=16.5).Φ =16.5 × 0.012=0.198.

3.4.Positioning the total error

Since the y direction welder servo system can automatically compensate，so x direction is determined weld neutral for welding error sensitive direction，therefore we only need to calculate the x direction，and take the various parameters into the equation［3］.

Analysis of the calculation results，so the error used outer edge positioning is lager than that of the inner positioning［4－5］.

Figure 6.The calculation diagram adopted cross outer edge and inner edge positioning

4.Conclusion

From the calculation process using the above two kinds of location methods can be seen:

1)Angle deviation of T－shaped steel in one direction greatest impact on the quality of welding，so fixed positioner of T－shaped steel should be used the adjustable device，so as to eliminate the influence of the angle error.

2)Locating surface is located inside the V slot，because of the neutral of V slot，manufacturing error of the welding equipment effect only the vertical direction，the wire feeding device can automatically compensate the positioning error in the vertical direction，thus positioning error caused by the devicemanufacturing can be regarded as 0.

3)The surface irregularities of T－shaped steel for the welding precision also has certain influence，locating surface is closer to thewelding point，the error will be decreased in proportion.Therefore，reducing the size ofwelding device is for improving the precision of welding favorable.But if the special welding device size is too small，itwill reduce the overall stability，so it is necessary to add auxiliary support，thereby increasing the contact stiffness.

The calculation results as a guide，designed welding device as shown in Figure 7，thewelding positioner is used to fix the relative position of T steel and H steel，in order to ensure the two sections on both sides，on each side of the beam mounting gasket，as adjustment device.In order to reduce the volume of the positioning device，making the positioning surface as close to the welding point，the driving wheel and driving guide rail set outside the welding positioner，the electric welding machine and wire scroll and an hourglass are fixed on themobile bearing，wire scroll and hourglass are connected with positioning device using a flexible hose connection，since only welded longitudinal displacement effect，will not bring additional error［6］.After reducing the volume of the positioning device，the floating support mechanism is designed to improve the rigidity of the welding positioning device，the lower edge of T－slot for the support，the pressure reliable and accurate positioning during the welding carriage movement process.At present，the device has been put into practical production.

Figure 7.The device structure of specialwelding

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十字型梁焊接定位方式的設計與計算*

趙敬云?，程雪利
河南機電高等?？茖W校，河南新鄉(xiāng) 453002

鋼結構廠房中的十字型梁沒有專門型材，需要兩種型材拼焊。由于結構限制，普通埋弧焊接設備無法施焊，且手工拼焊不能保證質量，需要設計專用焊接設備。為了保證十字形梁焊接精度，專用焊機設計前針對定位方式進行誤差計算，從而找出合理的定位方式，并制造出專用焊機投入生產，為鋼結構廠房中的十字型梁構件的加工方法提供參考。

十字型梁;拼焊;定位

TG441.1

10.3969/j.issn.1001－3881.2014.12.021

2014－02－15.