深中通道桥梁工程钢箱梁智能涂装技术

Intelligent Coating Techniques Used for Steel Box Girders in Bridges of Shenzhen-Zhongshan Link

深中通道桥梁工程钢箱梁制造总计约28万吨,钢箱梁制造节段数量多、涂装工作量大。为实现钢箱梁涂装提质增效,钢箱梁外表面和钢桥面采用自动化、智能化涂装生产线进行涂装,包括喷砂除锈、热喷锌铝、喷漆三部分。智能喷砂除锈设备采用喷砂机器人,由外部天车式喷砂机器人系统和地面轨道式喷砂机器人系统组成。智能喷锌铝设备采用热喷锌铝机器人,由2套喷涂小车组成,小车上搭载电弧喷涂电源、电弧喷枪系统和ABB机器人系统等。智能喷漆设备采用喷漆机器人,由2套轨道型多功能伸缩臂机器人系统组成。按照钢箱梁涂装工艺流程,分别采用喷砂机器人、热喷锌铝机器人和喷漆机器人进行相应的喷砂除锈、热喷锌铝和喷漆作业。通过涂装质量验收,喷砂机器人喷砂效率约为人工的4倍以上,一次合格率高;热喷锌铝机器人热喷锌铝效率约为人工的6倍,涂装膜厚均匀;喷漆机器人喷漆效率比人工略高,涂装膜厚均匀。智能化涂装技术提升了钢箱梁涂装质量,质量合格率为100%。

It consumed about 280000 t of steel in manufacturing the steel box girders for bridges of Shenzhen-Zhongshan Link project,and the coating of the large number of steel box girder segments was daunting.To improve the coating quality and efficiency,an automatic and intelligent coating production line was developed to paint the steel box girder surfaces and the steel deck,and the specific procedure included abrasive blasting,Zn-Al thermal spraying and painting.Blasting robots were employed,which consisted of the outside trolley-type blasting robot and ground orbital blasting robot.The Zn-Al thermal spraying robot was equipped with two trolleys for paint spraying,on which the arc spray power supplier,arc spray guns and ABB robotics were mounted.The painting robot contained two orbital multi-functional telescopic arm robot systems.To remove rusts,the abrasive blasting robot system and surface blasting facilities were started,and the rusts were blasted off following the procedure previously set.Afterwards,the intelligent Zn-Al spraying robot system and Zn-Al spraying facilities were switched on to complete the Zn-Al spraying work in accordance with the required procedure.After a full preparation,the related surface painting robot system was powered up to carry out painting following the designed procedure.The working efficiency of the intelligent painting and thermal spraying robots is four times of manual operation,the qualification rate of one-off operation is high and no repeated work is needed.The working efficiency of the Zn-Al thermal spraying robot is 6 times of manual spraying,and the thickness of dried coating would not surpass 120%of the design thickness.The working efficiency of the painting robot is slightly higher than manual painting,and the thickness deviation of dried coating can be effectively controlled less than 130%of the design thickness.The intelligent coating improves the coating quality and stability of the steel box girders.