Large 3D Flexible Welding Platform

3D Flexible Welding Platform Installation and Debugging Guide - Detailed Explanation from Foundation Construction to Precision Calibration
The installation and debugging of a 3D flexible welding platform are critical steps that determine its load-bearing stability and positioning accuracy. Especially in welding scenarios involving heavy engineering machinery components (such as 5-30 ton booms and arm frames), an unstable foundation can lead to platform settlement, while calibration deviations may cause weld misalignment and workpiece deformation. This article breaks down the entire process from "foundation construction → platform positioning → precision calibration → functional verification" to help you achieve "one-time installation and long-term stable operation."

I. Foundation Construction: Building a Solid Load-Bearing Base to Prevent Future Settlement
Foundation construction is the "groundwork" for platform stability, requiring attention to ground strength, flatness, and anchor bolt embedding. Key steps include:
1. Ground Preprocessing (Construction period: 7-10 days)
Strength Requirements: The installation ground must be C30 or higher concrete (lower grades are prone to cracking), with a pouring thickness ≥200mm. The concrete mix ratio should be "cement: sand: aggregate = 1:1.5:3." Antifreeze agents are required for winter construction to ensure compressive strength ≥30MPa after 28 days of curing.
Flatness Control: Use a laser leveling machine (accuracy ±2mm/10m) during pouring to achieve a surface error ≤5mm/2m. After curing, recheck with a 2-meter straightedge. Any deviations should be leveled with fast-drying epoxy mortar (thickness 5-10mm), ensuring flatness ≤0.1mm/m (≤0.08mm/m for heavy-duty platforms).
Moisture Prevention: When the workshop's relative humidity exceeds 60%, a 0.2mm thick moisture barrier should be laid under the concrete layer, with a 1‰ drainage slope to prevent moisture from causing platform corrosion.
2. Anchor Bolt Embedding (Synchronized with concrete pouring)
Specification Selection: Choose anchor bolts with a capacity 1.2 times the platform weight (e.g., M30×300mm high-strength bolts for a 50-ton platform), made of 45# steel (quenched and tempered) with tensile strength ≥800MPa.
Embedding Requirements: Mark positions according to the platform's bolt holes, with bolt spacing of 1.5-2m, embedding depth ≥150mm, and the top protruding 50mm above the ground (for leveling adjustments). Use fixed templates to ensure verticality error ≤1°, preventing issues with nut installation later.
II. Platform Positioning: Gentle Lifting, Stable Placement, and Precise Positioning
Platform positioning must avoid collision deformation, with controlled lifting angles and preliminary positioning. Key operational points include:
1. Lifting Preparation (Completed one day before lifting)
Tool Selection: Choose lifting equipment with a capacity 1.2 times the platform weight (e.g., a 50-ton mobile crane for a 30-ton platform). Use specialized nylon slings (load capacity ≥1.2 times the platform weight to avoid scratching the surface with wire ropes) and equip two 5-ton hand chain hoists for fine adjustments.
Platform Protection: Before lifting, cover the platform surface with a 3mm thick wear-resistant steel plate and place 10mm thick rubber pads at the four lifting points to prevent sling-induced dents. Inspect the platform for any transport-related deformations or burrs in T-slots and install warning signs.
2. Precise Positioning (Time required: 2-4 hours)
Angle Control: Keep the platform level during lifting (tilt angle ≤3°). Pause at 500mm above the ground for 10 minutes to check if the sling load is evenly distributed (avoiding unilateral stress deformation).
Temporary Support: After positioning, place 50mm high QT600 support blocks at the four corners to prevent direct contact with the ground and avoid debris entering the anchor bolt holes.
The installation and debugging of a 3D flexible welding platform require "precision at every step." Solid foundation construction ensures stability, precision calibration controls core accuracy, and functional verification eliminates potential issues. By following this guide, you can not only meet the precision requirements for heavy workpiece welding but also extend the platform's service life from 5 years to 8-10 years, providing a solid guarantee for the stable operation of your welding production line.
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