Semi-automatic turnout base plate welding production line and production method

Abstract

The semi-automatic turnout base plate welding production line comprises an upper computer, a robot controller, a PLC, a welding power source and a carrying robot. The transfer robot is arranged in the center of the production line layout; two parallel chain plate conveying lines are symmetrically arranged on the two sides of the carrying robot, and the carrying robot is arranged on the symmetric center line of the chain plate conveying lines. Manual grouping platforms are arranged at the starting ends of the two chain plate conveying lines correspondingly, welding platforms are arranged at the tail ends of the two chain plate conveying lines correspondingly, and the welding platforms are provided with welding robots; a feeding frame is arranged at the symmetrical center line position of the two manual team forming platforms. And a finished product pad is arranged at the symmetrical center line position of the two welding platforms. A semi-automatic production scheme combining manual assembly and automatic welding is adopted, semi-automatic welding production of various turnout base plate products with full specifications and complex structures is achieved, the turnout base plate welding production efficiency and the product quality are improved, and a new thought is provided for the industrial intelligent and automatic manufacturing technology.

Description

Technical Field

[0001] The invention belongs to the technical field of welding production of operating transportation turnout pads, and in particular relates to a semi-automatic turnout pad welding production line and a production method. Background Art

[0002] Turnout pads are key components of railway turnouts, supporting the track and positioning the rails, and require high precision. The basic structure of turnout pads includes pad bottom plates and small fasteners, which are connected as a whole by welding. Therefore, the welding quality directly affects the pad product quality and is closely related to the safety of railway line operation.

[0003] Railway turnouts have complex structures and require a variety of types and specifications of pads, mainly flat pads, slide bed pads, switch pads, frog pads and guardrail pads. In addition, the product size accuracy requirements are high, resulting in heavy production tasks for factories and great difficulty in processing and manufacturing.

[0004] At present, the assembly and welding process of turnout pad parts mainly rely on two methods: manual or automated welding. The manual production method is labor-intensive and requires high skill levels of welders. The welding quality is greatly affected by human factors, resulting in low production efficiency and unstable product quality of pad products. The fully automated welding production method of turnout pads can only cover a small number of pad products with simple structures and uniform specifications, and the excessive pursuit of automation of the entire production process can easily lead to unreasonable production process settings. Specifically, the loading and unloading of pad parts and the positioning and assembly of parts are cumbersome and time-consuming, resulting in poor continuity of production steps, unstable time rhythm, and the inability to improve production efficiency. In this regard, the following improved technical solutions are proposed. Summary of the invention

[0005] The technical problem solved by the present invention is: to provide a semi-automatic turnout pad welding production line and production method, adopt a semi-automatic production solution combining manual assembly with automatic welding, realize the semi-automatic welding production of complex structure turnout pad products of various types and full specifications, and improve the turnout pad welding production efficiency and product quality.

[0006] The technical solution adopted by the present invention is: a semi-automatic turnout pad welding production line, including a host computer, a robot controller, a PLC controller, and a welding power supply.

[0007] It also includes a handling robot; the handling robot is arranged at the center of the production line layout; two parallel chain conveyor lines are symmetrically arranged on both sides of the handling robot, and the handling robot is arranged on the symmetrical center line of the chain conveyor lines; manual teaming platforms are respectively arranged at the starting ends of the two chain conveyor lines, and welding platforms are respectively arranged at the ends of the two chain conveyor lines, and the welding platforms are equipped with welding robots; loading racks are arranged at the symmetrical center lines of the two manual teaming platforms; finished product material pads are arranged at the symmetrical center lines of the two welding platforms.

[0008] In the above technical scheme, as the preferred technical scheme of the present invention, an electromagnetic adsorption extension clamp is provided at the handling end of the handling robot; the electromagnetic adsorption extension clamp controls the clamp change through a PLC controller, and is used to grab the pad bottom plate and complete the pad bottom plate loading and pad finished product unloading.

[0009] In the above technical scheme, as a further improvement of the present invention, a position sensor Ⅰ and a character recognition sensor are arranged on the chain conveyor line; the position sensor Ⅰ is used to detect whether the position of the pad to be welded reaches the pad character recognition detection position; the character recognition sensor is used to identify the characters of the pad to be welded, and is used to determine the type and specifications of the pad to be welded, and upload the character recognition results to the host computer, the host computer processes the character recognition results, and sends instructions to the welding robot and the handling robot through the robot controller 1 to execute the automatic welding program and the automatic unloading program corresponding to the pad characters.

[0010] In the above technical scheme, as a further improvement of the present invention, the manual teaming platform is provided with a control button Ⅰ and a status indicator light Ⅰ; the control button Ⅰ is used to manually control the loading process of the handling robot and the material transfer process of the chain conveyor line; the manual teaming platform is provided with a guide bar; the guide bar is used to accurately fix the position of the pad to be welded near the center axis of the chain conveyor line.

[0011] In the above technical scheme, as a further improvement of the present invention, a semi-enclosed protective cover is provided on the outside of the welding robot; the host computer, the robot controller, the PLC controller, and the welding power supply are arranged on the outside of the protective cover and close to the manual teaming platform.

[0012] In the above technical scheme, as a further improvement of the present invention, the welding position of the welding platform is provided with rollers, a position sensor II, a lifting device and a clamping device; the rollers are used to continuously and smoothly convey the pad to be welded to the welding position of the welding robot; after the position sensor II detects that the pad to be welded has reached the specified position, the lifting device lifts and fixes the pad position through the position of the pad bottom plate hole, and the clamping device clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0013] In the above technical scheme, as the preferred technical scheme of the present invention, a welding assembly is provided at the execution end of the welding robot; the welding assembly is connected to the welding power supply, the welding cooling water tank and the shielding gas delivery pipeline; the welding method of the welding robot is metal-metal gas shielded welding.

[0014] In the above technical solutions, as the preferred technical solution of the present invention, both the welding robot and the handling robot complete program programming through the teaching pendant.

[0015] In the above technical solution, as a further improvement of the present invention, a control button II and a status indicator light II are provided on the robot controller; the control button II is used for the operator to shut down the equipment in time in an emergency.

[0016] The present invention also claims protection for a semi-automatic turnout pad welding production method, the production method is a production method of any semi-automatic turnout pad welding production line, and the production method comprises the following steps:

[0017] Step 1: Check the power supply;

[0018] Step 2: Manually control automatic loading;

[0019] Step 3: Manual pairing;

[0020] Step 4: Manually control the conveying;

[0021] Step 5: Character recognition;

[0022] Step 6: Automatically transport to the welding position;

[0023] Step 7: Automatically position and fix the pad;

[0024] Step 8: Automatically weld the backing plate;

[0025] Step 9: After welding is completed, the clamping device and the lifting device are released;

[0026] Step 10: Automatic unloading;

[0027] Repeat steps 1 to 10 to achieve continuous semi-automatic welding production of pad products.

[0028] In the above technical solution, as a further improvement of the present invention:

[0029] In step 1: Check to ensure that the equipment, fixtures and various status indicators are working properly, place neatly stacked pallet base plates on the loading rack, prepare the pallet assembly for positioning templates and small pallet pieces, and power on the equipment when ready.

[0030] In step 2: manually press the loading control button Ⅰ, the handling robot starts to move, and after scanning the stacked pallet bottom plate with 3D vision, it automatically grabs the pallet bottom plate and places it on the manual teaming platform.

[0031] In step 3: with the help of the pad base plate assembly positioning template, the pad base plate and parts are manually assembled and spot welded.

[0032] In step 4: manually press the start control button Ⅰ of the chain conveyor line, the chain conveyor line starts to run, and the side of the bottom plate of the pad to be welded is brought close to the guide baffle bar, and the bottom plate of the pad to be welded is manually transferred to the chain conveyor line.

[0033] In step 5: when the position sensor I detects that the bottom plate of the pad to be welded reaches the detection position of the character recognition sensor, the chain conveyor line stops conveying and the character recognition sensor starts to recognize the character mark of the bottom plate of the pad.

[0034] In step 6: the character recognition sensor sends the character recognition result to the host computer and the robot controller 1. After the processing is completed, the chain plate conveyor line starts to run and conveys the base plate to be welded to the welding robot working position.

[0035] In step 7: after the position sensor II of the welding robot detects that the pad bottom plate has reached the designated welding operation position, the lifting device fixes the pad bottom plate position through the pad bottom plate holes, and the clamping device clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0036] In step 8: the welding robot executes the welding program corresponding to the character mark of the pad and automatically performs pad welding.

[0037] In step 9: After welding is completed, the clamping device and the lifting device are released.

[0038] In step 10: the handling robot grabs the finished pad, automatically unloads and places it on the dedicated finished material pad.

[0039] The advantages of the present invention compared with the prior art are:

[0040] 1. The present invention combines the flexibility of manual work with the high efficiency of the automated welding production line to realize the automated welding production of complex structure turnout pad products of various types and full specifications, thereby improving the welding production efficiency and product quality of turnout pads.

[0041] 2. The present invention can solve the problem of robotic automated industrial production of complex product categories through semi-automated production methods, and provides new ideas for industrial intelligence and automated manufacturing technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is a schematic diagram of the layout structure of the semi-automatic turnout pad welding production line of the present invention;

[0043] Figure 2 For the present invention Figure 1 A schematic diagram of the enlarged structure of the welding platform;

[0044] Figure 3 This is a flow chart of the semi-automatic turnout pad welding production method of the present invention;

[0045] In the figure: 1-robot controller, 2-PLC controller, 3-welding power supply, 4-handling robot 4, 5-chain conveyor line, 6-artificial team platform, 61-guide bar, 7-welding robot, 71-roller, 72-position sensor II, 73-lifting device, 74-clamping device, 8-loading rack, 9-finished material pad, 10-protective cover, 11-welding platform. DETAILED DESCRIPTION

[0046] The following will be combined with the attached embodiment of the present invention Figure 1-3 , the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0047] A semi-automatic turnout pad welding production line (such as Figure 1 The welding power supply is connected to the welding robot 7; the host computer is connected to the input end of the PLC controller 2, the output end of the PLC controller 2 is connected to the input end of the robot controller 1, and the output end of the robot controller 1 is connected to the welding robot 7 and the handling robot 4.

[0048] The working principle is as follows: the host computer establishes a connection with the PLC controller 2 through Ethernet, serial communication or wireless communication. As the monitoring and control center, the host computer is responsible for sending control instructions to the PLC controller 2 and receiving data and status information fed back by the PLC controller 2. The PLC controller 2 is connected to the robot controller 1 through IO interface, serial communication or Ethernet communication. According to the instructions and program logic of the host computer, the PLC controller 2 sends control signals to the robot controller 1 to achieve precise control of the welding robot 7 and the handling robot 4. The robot controller 1 is the core component of the welding robot 7 and the handling robot 4, which is responsible for receiving the control signal of the PLC controller 2 and converting it into specific action instructions of the welding robot 7 and the handling robot 4. The welding robot 7 and the handling robot 4 are connected to the robot controller 1 through cables or buses to realize signal transmission and execution of control instructions. This connection method realizes a complete control chain from upper-level monitoring to bottom-level execution, and improves the overall performance and reliability of the system. The host computer provides a friendly human-computer interaction interface, which is convenient for operators to monitor and operate the welding robot 7 and the handling robot 4. As an intermediate link, the PLC controller 2 realizes precise control and data exchange of the robot controller 1, ensuring the stability and real-time performance of the system. The robot controller 1 focuses on controlling the specific actions of the welding robot 7 and the handling robot 4, improving the control accuracy and efficiency.

[0049] (like Figure 1 The transport robot 4 is also provided at the center of the production line layout; placing the transport robot 4 at the center of the production line can make the distance to each production station or processing area relatively balanced and short, thereby shortening the time and distance of material handling and improving the material flow efficiency of the entire production line. The layout at the center helps to achieve more efficient material scheduling and distribution, reduce waiting time in the production process, and improve the overall output rate of the production line. The transport robot 4 at the center can maximize the use of production space through reasonable path planning and motion control, reduce the additional space occupied by material handling, and improve the space utilization rate of the production workshop. Placing the transport robot 4 at the center of the production line is convenient for operators and managers to monitor and maintain it centrally, and to discover and solve problems in a timely manner.

[0050] Two straight and parallel chain conveyor lines 5 are symmetrically arranged on both sides of the handling robot 4, and the handling robot 4 is set on the symmetrical center line of the chain conveyor lines 5. The chain conveyor lines 5 serve as the main channel for material transmission. Their parallel and symmetrical layout enables the materials to be smoothly and efficiently transmitted to the working area of ​​the handling robot. The handling robot 4 works between the two chain conveyor lines 5 and can complete the material handling task without long-distance movement, thereby reducing idle time and energy consumption. This layout improves the parallel processing capability of the production line and greatly increases the material processing volume per unit time. The chain conveyor lines 5 are symmetrically arranged on both sides of the handling robot 4, making the layout of the entire production line more compact and reasonable, which not only saves production space, but also makes the overall appearance of the production line more neat and beautiful.

[0051] The starting ends of the two chain plate conveyor lines 5 are respectively provided with a manual teaming platform 6, and the ends of the two chain plate conveyor lines 5 are respectively provided with a welding platform 11, and the welding platform 11 is equipped with a welding robot 7; a loading rack 8 is provided at the symmetrical midline position of the two manual teaming platforms 6; and a finished material pad 9 is provided at the symmetrical midline position of the two welding platforms 11. The setting of the manual teaming platform 6 enables the materials to be sorted and placed on the chain plate conveyor line in an orderly and rapid manner during the loading stage. The operator can conduct a preliminary inspection and sorting of the materials on the manual teaming platform 6 to ensure that the materials enter the production line in the correct direction and sequence. Since the loading rack 8 is located at the symmetrical midline position of the two manual teaming platforms 6, the operator can conveniently provide materials for the chain plate conveyor lines 5 on both sides at the same time, reducing the waiting time for loading and improving production efficiency. The chain plate conveyor line 5 serves as a bridge for material transmission, and closely connects the manual teaming platform 6 with the welding robot 7. Driven by the chain plate conveyor line 5, the materials are automatically transmitted to the welding robot 7 for welding operations, realizing seamless connection of the production process. The flexibility and adaptability of the chain plate conveyor line 5 allow the production process to be adjusted according to actual needs: for example, when the welding robot 7 on one side fails or requires maintenance, the operator can quickly adjust the running direction or speed of the chain plate conveyor line to ensure that the welding robot 7 on the other side can continue to work and maintain the continuity and stability of the production line. Handing over the welding work to the welding robot 7 can reduce the occurrence of manual intervention and human errors. At the same time, the welding robot 7 can work in harsh environments, reducing the labor intensity and risks of workers. The setting of the finished material pad 9 allows the welded turnout pads to be stored and stacked in an orderly manner. This not only facilitates the management and inventory of finished products, but also provides convenience for subsequent packaging, transportation and other processing links. The finished material pad 9 is located at the symmetrical midline position of the two welding robots 7, so that the finished products can be stored in a centralized manner and maximize the use of space resources. This layout method also helps to reduce the distance and time cost of material handling.

[0052] In the above embodiment, as a preferred embodiment of the present invention, the handling end of the handling robot 4 is provided with an electromagnetic adsorption extension clamp; the electromagnetic adsorption extension clamp controls the clamp change through the PLC controller 2, and is used to grab the pad bottom plate and complete the pad bottom plate loading and pad finished product unloading.

[0053] Among them, the electromagnetic adsorption extension fixture uses the electromagnetic principle to achieve rapid adsorption and release of the pad bottom plate. This non-contact grasping method not only improves the grasping efficiency, but also avoids the material damage that may be caused by traditional mechanical fixtures. Through the precise control of the PLC controller 2, the electromagnetic adsorption extension fixture can accurately identify and grasp the position of the pad bottom plate, ensuring the accuracy and stability of material handling. The PLC controller 2 supports the automatic control of fixture changeover, so that the handling robot can quickly change the fixture type according to different production needs to adapt to pad bottom plates of different sizes, shapes and weights. Automated handling and fixture changeover reduce manual intervention and labor costs, and reduce the operating costs of the enterprise. The electromagnetic adsorption extension fixture and PLC controller 2 usually adopt a modular design for easy maintenance and replacement. At the same time, the programming and maintenance of the PLC controller 2 are relatively simple, which reduces the technical threshold and maintenance costs. The electromagnetic adsorption extension fixture can adapt to pad bottom plates of different materials, sizes and shapes, and has strong adaptability.

[0054] In the above embodiment, as a further improved embodiment of the present invention, a position sensor Ⅰ and a character recognition sensor are arranged on the chain conveyor line 5; the position sensor Ⅰ is used to detect whether the position of the pad to be welded reaches the pad character recognition detection position; the character recognition sensor is used to identify the characters of the pad to be welded, to determine the type and specification of the pad to be welded, and to upload the character recognition results to the host computer, the host computer processes the character recognition results, and sends instructions to the welding robot 7 and the handling robot 4 through the robot controller 1 to execute the automatic welding program and the automatic unloading program corresponding to the pad characters.

[0055] Among them, the position sensor I can detect the position of the pad to be welded in real time, ensuring that it triggers the character recognition sensor for character recognition when it reaches the specified position. This process is fully automated and does not require human intervention, greatly improving production efficiency. After the character recognition sensor recognizes the characters of the pad to be welded, it uploads the results to the host computer. Based on the recognition results, the host computer sends instructions to the welding robot and the handling robot through the robot controller to execute the automatic welding program and automatic unloading program corresponding to the pad characters. This process realizes full automation from detection to execution. The character recognition sensor can accurately identify the characters on the pad to be welded, thereby determining the type and specifications of the pad. This precise recognition capability avoids the errors that may be caused by human judgment and ensures the accuracy and consistency of production. According to the character recognition results, the welding robot and the handling robot can execute the corresponding welding and unloading programs, realizing customized production of pads of different types and specifications. Through real-time monitoring and recognition, the pad to be welded can quickly enter the next production link, reducing the time wasted waiting for recognition or classification. Automated detection and recognition reduce the degree of human participation and reduce the dependence on skilled workers.

[0056] In the above embodiment, as a further improved embodiment of the present invention, the manual teaming platform 6 is provided with a control button Ⅰ and a status indicator light Ⅰ; the control button Ⅰ is used to manually control the loading process of the handling robot 4 and the material transfer process of the chain conveyor line 5; the manual teaming platform 6 is provided with a guide bar 61; the guide bar 61 is used to accurately fix the position of the pad to be welded near the central axis of the chain conveyor line 5.

[0057] Among them, through the manual control button Ⅰ, the operator can easily control the loading process of the handling robot 4 and the material transfer process of the chain plate conveyor line 5. This direct control method makes the operation more intuitive and convenient, and also improves the precision and accuracy of the control. The status indicator Ⅰ can display the operating status of the handling robot and the chain plate conveyor line in real time, helping the operator to understand the production situation in time and make corresponding adjustments. This visual feedback mechanism improves the controllability and safety of the production process. The guide baffle 61 is designed to accurately fix the position of the pad to be welded near the central axis of the chain plate conveyor line 5. This design can ensure that the pad maintains a stable posture and position during the conveying process, avoiding welding errors or quality problems caused by position offset. At the same time, it also simplifies the grasping and positioning process of the handling robot, and improves production efficiency and accuracy. The control button Ⅰ and the status indicator Ⅰ on the manual team platform 6 combine manual control with automated production, which not only retains the flexibility and accuracy of manual intervention, but also gives play to the efficiency and stability of automated production. This combination makes the production line more flexible and reliable, and can adapt to changes in different production needs. The setting of the control button Ⅰ and the status indicator Ⅰ also takes into account the safety of the production line. The operator can stop the operation of the handling robot 4 and the chain conveyor line 5 at any time through the control button Ⅰ to avoid accidents. At the same time, the real-time feedback of the status indicator Ⅰ can also help the operator to timely discover potential safety hazards and take corresponding measures.

[0058] In the above embodiment, as a further improved embodiment of the present invention, a semi-enclosed protective cover 10 is provided on the outside of the welding robot 7; the host computer, the robot controller 1, the PLC controller 2, and the welding power supply 3 are arranged on the outside of the protective cover 10 and close to the manual team platform 6.

[0059] Among them, the semi-enclosed protective cover 10 provides a physical barrier for the welding robot 7, effectively preventing the spatter, high-temperature sparks, etc. generated during the welding process from directly harming the operator or other equipment, and significantly reducing the safety risks at the production site. The key equipment such as the host computer, the robot controller 1, the PLC controller 2 and the welding power supply 3 are arranged outside the protective cover 10 and close to the manual teaming platform 6, which is convenient for the operator to monitor and maintain, and avoids these precision equipment from being directly exposed to the harsh welding environment, reducing equipment failure and damage caused by environmental factors. Pollutants such as smoke and harmful gases generated during the welding process are partially isolated by the protective cover, reducing the pollution of these pollutants to the production environment, and helping to keep the production site clean and tidy. The noise generated by the welding robot 7 during operation is also partially absorbed and isolated by the protective cover 10, reducing the noise level at the production site and providing a more comfortable working environment for the operator. The design of the protective cover 10 reduces the interference of external factors on the welding robot 7 and its control equipment, such as dust, moisture, etc., thereby improving the reliability and stability of the equipment. Placing key equipment outside the protective cover 10 facilitates operators to quickly approach and operate these equipment during daily maintenance and overhaul, thereby improving the convenience and efficiency of maintenance. When an abnormal situation occurs on the production line, the operator can quickly intervene and adjust through the host computer or robot controller 1 to ensure the continuity and stability of production.

[0060] In the above embodiment, as a further improved embodiment of the present invention, the welding position of the welding platform 11 is provided with a roller 71, a position sensor II 72, a lifting device 73 and a clamping device 74; the roller 71 is used to continuously and smoothly convey the pad to be welded to the welding position of the welding robot 7; after the position sensor II 72 detects that the pad to be welded has arrived at the specified position, the lifting device 73 lifts and fixes the pad position through the position of the pad bottom plate hole, and the clamping device 74 clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0061] Among them, through the continuous and smooth conveying of the roller 71, the pad to be welded can accurately reach the welding position of the welding robot 7. This conveying method not only improves production efficiency, but also ensures the stability and consistency of the pad during the conveying process, laying a good foundation for subsequent welding operations. The position sensor II 72 can detect the position of the pad to be welded in real time and send a signal when it reaches the specified position. This precise position detection capability ensures the accuracy and reliability of the welding operation and avoids welding quality problems caused by position deviation. After receiving the signal from the position sensor II 72, the lifting device 73 quickly moves to lift the pad to be welded to a certain height and fix it through the position of the pad bottom plate hole. This fixing method is not only stable and reliable, but also can adapt to pads of different specifications and sizes, improving the flexibility and adaptability of the welding operation. After the pad is lifted to the specified position and fixed, the clamping device 74 immediately clamps the pad bottom plate to further ensure the stability and position of the pad during the welding process. This double fixing method greatly improves the accuracy and reliability of the welding operation. The coordinated work of roller 71, position sensor II 72, lifting device 73 and clamping device 74 enables the welding robot to quickly and accurately complete the conveying, positioning and fixing of the pad to be welded, which not only improves the efficiency of the welding operation, but also ensures the stability and consistency of the welding quality. The entire welding operation process is highly automated, reducing the links of manual intervention and the possibility of errors, which not only reduces labor intensity, but also improves production efficiency and product quality. By adjusting the working parameters of the lifting device 73 and the clamping device 74, the system can adapt to welding operations on pads of different specifications and sizes. This flexibility enables the production line to easily cope with changes in production requirements for different products. Since the entire welding operation process is highly automated and standardized, the production line can quickly respond to changes in market demand and adjust production plans and product specifications to meet customer needs.

[0062] In the above embodiment, as a preferred embodiment of the present invention, the execution end of the welding robot 7 is provided with a welding assembly; the welding assembly is connected to the welding power supply 3, the welding cooling water tank and the shielding gas delivery pipeline; the welding method of the welding robot 7 is metal-metal gas shielded welding.

[0063] Among them, the use of the metal-metal arc welding method can form a smooth and uniform weld with a beautiful appearance, reducing the workload of subsequent grinding and finishing. The welding robot 7 can work continuously without interruption, without being restricted by fatigue and rest time, greatly improving production efficiency. The metal-metal arc welding method has a high welding speed and can complete a large number of welding tasks in a short time. The welding robot 7 can automatically identify the welding position and adjust the welding parameters through built-in programs and sensors to achieve fully automated welding. Automated welding reduces the manual operation links and reduces the impact of human factors on welding quality. The metal-metal arc welding method uses inert gas (such as argon, helium, etc.) as a protective gas, which effectively prevents harmful reactions such as oxidation and nitridation generated during the welding process and protects the welding quality. Automated welding reduces the generation of pollutants such as welding smoke and spatter, improves the working environment, and reduces the health hazards to operators. The welding assembly adopts a modular design for easy installation, maintenance and replacement. The welding cooling water tank can cool the welding gun head in time, maintain the stability of the welding process, and extend the service life of the equipment. The shielding gas delivery pipeline ensures a stable supply of shielding gas and avoids gas interruption problems during welding.

[0064] In the above embodiment, as a preferred embodiment of the present invention, the welding robot 7 and the handling robot 4 are both programmed by a teach pendant. Teach pendant programming allows the operator to intuitively create instructions and work paths by physically moving the robot or using a control device to operate, and does not require the operator to have in-depth programming knowledge, which reduces the skill threshold and enables non-professionals to quickly master operating skills. Due to the intuitiveness and ease of use of teaching programming, operators can quickly become familiar with and master programming methods, shorten the training cycle, and improve production efficiency. Teaching programming allows operators to modify and optimize programs immediately after field trial and error. This flexibility enables the robot to quickly adapt to changes in production lines or production needs of new products, reducing downtime and production delays. Whether it is a simple assembly task or a complex welding, handling and other operations, teaching programming can provide an effective solution. Compared with traditional manual programming or text-based programming, teaching programming can greatly increase programming speed. Operators can quickly run the equipment and conduct field trial and error and debugging, thereby shortening the programming cycle. Since teaching programming reduces the requirements for operator skills, enterprises can reduce their dependence on professional programmers and reduce labor costs. At the same time, efficient programming methods also help improve production efficiency and product quality, and further reduce production costs. Teaching programming provides a safe and effective solution. Through pre-set programs and paths, robots can accurately and stably complete tasks, avoiding casualties and property losses. Teaching programming can ensure the accuracy and stability of robots when performing tasks. Through multiple teaching and optimization, robots can perform operations according to predetermined paths and parameters, improving the quality and consistency of operations. Teaching programming is usually closely integrated with the robot's control system, which is convenient for integration with other equipment and systems. Teaching programming programs are easy to copy, edit and transfer. When equipment fails or needs adjustment, technicians can quickly locate the problem and modify the program to ensure the normal operation and production efficiency of the equipment.

[0065] In the above embodiment, as a further improved embodiment of the present invention, the robot controller 1 is provided with a control button II and a status indicator light II; the control button II is used by the operator to shut down the equipment in time in an emergency, thereby improving the safety of use. The control button II and the status indicator light II provided on the robot controller 1 provide the operator with a means to shut down the equipment in time in an emergency, which has significant technical advantages such as improving safety, enhancing emergency response capabilities, enhancing operator confidence, and facilitating troubleshooting and maintenance.

[0066] (like Figure 3 The present invention also claims a semi-automatic turnout pad welding production method, the production method is any of the semi-automatic turnout pad welding production lines, the production method comprises the following steps:

[0067] Step 1: Check the power supply;

[0068] Step 2: Manually control automatic loading;

[0069] Step 3: Manual pairing;

[0070] Step 4: Manually control the conveying;

[0071] Step 5: Character recognition;

[0072] Step 6: Automatically transport to the welding position;

[0073] Step 7: Automatically position and fix the pad;

[0074] Step 8: Automatically weld the backing plate;

[0075] Step 9: After welding is completed, the clamping device and the lifting device are released;

[0076] Step 10: Automatic unloading;

[0077] Repeat steps 1 to 10 to achieve continuous semi-automatic welding production of pad products.

[0078] Complex pad products have many weld positions and a large total weld length. The semi-automatic turnout pad welding production method of the present invention is adopted. During the robot's automatic welding process, the subsequent pads are manually assembled and spot-welded to ensure continuous feeding of the pads to be welded, eliminating the problems of long idle periods of welding robots and discontinuous work processes caused by the fully automatic loading operation mode; the production rhythm is stable and the efficiency is improved.

[0079] In the above embodiment, as a further improved embodiment of the present invention, the following steps are included:

[0080] In step 1: check and ensure that the equipment, fixtures and various status indicator lights are working properly, place neatly stacked pallet base plates on the loading rack 8, prepare the pallet assembly for positioning templates and small pallet pieces, and power on the equipment when ready.

[0081] The pre-check and preparation in step 1 can ensure that the production process is in the best condition at the start-up, reducing downtime caused by equipment failure or insufficient material preparation. The neatly stacked pallet base can be quickly identified and grabbed by the equipment, speeding up the production rhythm. The accuracy of the fixture and positioning template is crucial to ensure the accuracy of the pad assembly. Checking and preparing in advance can ensure that these tools are in good condition, thereby avoiding errors in the assembly process and improving product quality. The normal operation of the status indicator can provide real-time feedback on the equipment status, timely discover and solve problems, and prevent defective products caused by equipment abnormalities. A comprehensive inspection before the equipment is started can promptly discover and eliminate potential safety hazards, such as aging of electrical circuits and loose mechanical parts, to ensure the safety of personnel and equipment during the production process.

[0082] In step 2: manually press the loading control button I, the handling robot 4 starts to move, and after scanning the stacked pallet bottom plate with 3D vision, it automatically grabs the pallet bottom plate and places it on the manual teaming platform 6.

[0083] The introduction of the handling robot 4 in step 2 significantly improves the automation level of the production line. Through preset programs and advanced sensor technology, the robot can autonomously complete the entire process from identification to grasping and then to placement, reducing the need for human intervention. 3D visual scanning technology provides the handling robot with high-precision recognition capabilities. By quickly capturing and analyzing information such as the shape, size, and position of the base plate of the pad, the robot can accurately select the target and grasp it, improving the accuracy and efficiency of the operation. The automated grasping and placement process avoids the errors and delays that may be caused by manual operation, ensuring the smooth progress of the production process. Automated operation reduces the chance of direct contact between personnel and heavy materials, and reduces the risk of accidental injuries that may occur during the handling process. The use of handling robots reduces the demand for human resources, especially in the handling of heavy objects and repetitive labor, which helps companies reduce labor costs.

[0084] In step 3: with the help of the pad base plate assembly positioning template, the pad base plate and parts are manually assembled and spot welded.

[0085] Step 3 Using the positioning template for the grouping operation can ensure that the assembly of each pad bottom plate and parts follows the same standards and requirements, thereby ensuring the consistency and stability of the assembly results. The positioning template simplifies the tedious steps in the assembly process, allowing operators to complete the grouping operation faster. At the same time, the markings and instructions on the template also reduce the difficulty of operation and improve the work efficiency of the operator. Due to the improvement of assembly accuracy, the use of the positioning template for grouping operations can significantly reduce the rework rate caused by assembly errors, which not only saves time and labor costs, but also improves the overall production efficiency. Accurate grouping and spot welding fixation operations can ensure that the connection between the pad bottom plate and the parts is firm and reliable, thereby enhancing the stability of the entire structure, which is of great significance for improving the service life and safety of the product. The use of the positioning template ensures that the assembly results meet the design requirements and specifications, and avoids quality problems caused by improper assembly. The markings and positioning holes on the positioning template make the quality control and inspection in the assembly process more intuitive and convenient. Operators can easily check whether the assembly results meet the requirements and find and correct problems in time. Using positioning templates for assembly operations helps to achieve standardized management of the production process. By establishing unified assembly standards and processes, companies can better control product quality and production efficiency.

[0086] In step 4: manually press the chain plate conveyor line start control button I, the chain plate conveyor line 5 starts to run, and one side of the base plate to be welded is brought close to the guide baffle 61, and the base plate to be welded is manually transferred to the chain plate conveyor line 5.

[0087] By manually pressing the start control button, the chain plate conveyor line 5 can respond quickly and start running. This process realizes the initial triggering of automation. While the chain plate conveyor line 5 is running, the bottom plate of the pad to be welded is manually placed accurately on the conveyor line. This human-machine collaborative working mode gives full play to the stability of the automation equipment and the flexibility of manual operation, and improves the overall operation efficiency. The side of the bottom plate of the pad to be welded is placed close to the guide baffle 61. This design helps to achieve accurate positioning and guiding of the bottom plate of the pad, reducing the risk of offset and misalignment. Accurate positioning and guiding provide a good foundation for subsequent operations such as spot welding and fixing, which helps to improve the assembly accuracy and product quality of the entire production process. Through the conveying process of the chain plate conveyor line 5, the need for manual handling of heavy objects is reduced, thereby reducing the risk of personal injury caused by improper handling. As a mature conveying equipment, the chain plate conveyor line 5 has high stability and reliability, and can operate stably for a long time without failure or shutdown.

[0088] In step 5: when the position sensor I detects that the bottom plate of the pad to be welded reaches the detection position of the character recognition sensor, the chain plate conveyor line 5 stops conveying, and the character recognition sensor starts to recognize the character mark of the bottom plate of the pad.

[0089] The precise detection of position sensor Ⅰ in step 5 ensures that the pad bottom plate will be recognized only when it reaches a specific position, avoiding recognition errors caused by non-fixed position during movement. The suspension of the chain conveyor line 5 provides a stable recognition environment for the character recognition sensor, reduces the vibration and interference caused by material movement, and thus improves the accuracy and reliability of recognition. Once the position sensor Ⅰ detects that the pad bottom plate has reached the specified position, the chain conveyor line can respond quickly and suspend the conveying. The efficient connection of this process reduces waiting time and improves overall production efficiency. The automatic recognition function of the character recognition sensor replaces the traditional manual inspection method, realizes the automation and intelligence of the production process, and reduces labor costs and error rates. The character recognition sensor can recognize the character marks on different pad bottom plates, which enables the production line to flexibly respond to the production needs of products of different models and specifications. By identifying the character marks on the pad bottom plate, the unique identification and traceability of the product can be achieved, which helps to quickly locate the cause and take corresponding measures when problems occur.

[0090] In step 6: the character recognition sensor sends the character recognition result to the host computer and the robot controller 1. After the processing is completed, the chain plate conveyor line 5 starts to run and conveys the base plate to be welded to the working position of the welding robot 7.

[0091] In step 6, the information transmission between the character recognition sensor and the host computer and robot controller 1 is carried out in real time, ensuring the immediacy and accuracy of the recognition results. The host computer and robot controller 1 have powerful data processing capabilities and can quickly analyze and process the received character recognition results to provide accurate guidance for subsequent welding operations. The entire process achieves a high degree of automated control, from character recognition to the start and stop of the conveyor line, to the operation preparation of the welding robot, all of which are automatically completed through preset programs and algorithms, reducing the need for manual intervention. Through the coordinated work of the character recognition sensor and the chain plate conveyor line 5, the precise positioning of the bottom plate of the welding pad before welding can be ensured, providing a stable working environment for the welding robot. After receiving the signal that the processing is completed, the chain plate conveyor line 5 can quickly start and continue to convey materials, realizing the continuity and efficiency of the production process.

[0092] In step 7: after the position sensor II 72 of the welding robot 7 detects that the pad bottom plate has reached the designated welding operation position, the lifting device 73 fixes the pad bottom plate position through the pad bottom plate holes, and the clamping device 74 clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

[0093] Step 7 The high-precision detection capability of the position sensor II 72 ensures that the welding robot 7 can accurately identify the welding operation position reached by the pad bottom plate, providing a solid foundation for subsequent fixation and welding operations. The lifting device 73 is fixed through the holes on the pad bottom plate. This design not only improves the stability of the fixation, but also reduces the risk of displacement caused by external forces. At the same time, the clamping action of the clamping device 74 further enhances the fixing effect of the pad bottom plate, ensuring that the position remains unchanged during the welding process. High-precision positioning and fixation reduce errors and deviations during the welding process. The entire process from the detection of the pad bottom plate to fixation and then to the welding operation has realized automated control, reducing the need for manual intervention, improving the level of automation in the production process, and reducing the risk of safety accidents caused by human factors.

[0094] In step 8: welding robot 7 executes the welding program corresponding to the character mark of the pad and automatically performs pad welding. Through advanced control systems and sensor technology, welding robot 7 can accurately control various parameters in the welding process, such as welding current, voltage, speed, angle, etc., to ensure the accuracy of welding. Compared with manual welding, welding robot 7 can maintain a high degree of consistency in welding quality, avoid welding deviations and defects caused by human factors, and thus improve the overall quality of the product. Welding robot 7 can continuously and stably perform welding operations without rest or shifts, greatly improving production efficiency. Welding robot 7 can operate in harsh environments such as high temperature and high smoke, reducing the safety risks faced by workers. Welding robot 7 uses high-quality mechanical structure and electrical components, has high reliability and stability, and can operate stably for a long time without failure. After teaching programming, welding robot 7 can realize precise control of various complex actions, and can automatically select the corresponding welding program according to the character mark on the pad, which improves the flexibility and adaptability of production. The automated production of welding robot 7 reduces dependence on labor and reduces labor cost expenditure.

[0095] In step 9: after welding is completed, the clamping device 74 and the lifting device 73 are released. After welding is completed, the automatic release of the clamping device 74 and the lifting device 73 is an important part of the welding automation process. This seamless connection reduces the need for manual intervention and improves the automation level of the overall production process. Automatic release can respond quickly, reduce waiting time, and enable the next production link to proceed immediately, thereby improving overall production efficiency. The clamping device 74 and the lifting device 73 are designed with the need for precise control in mind. After welding is completed, they can accurately release the clamping and fixation of the base plate, avoiding damage to the product caused by incomplete or excessive loosening. Automatic release reduces the direct contact between workers and dangerous factors such as high temperature and high pressure, and reduces the risk of industrial accidents. Timely release of the clamping device 74 and the lifting device 73 also helps protect welding robots and other related equipment, avoiding equipment damage caused by long-term stress or jamming. Automatic release reduces the uncertainty and error of manual operation, reduces the degree of wear on the clamping device and the lifting device, and thus extends the service life of the equipment. Since the possibility of manual intervention and misoperation is reduced, the maintenance process of the automated release operation is also simplified, reducing maintenance costs and difficulty.

[0096] In step 10: the handling robot 4 grabs the finished pad, automatically unloads and places it on the special finished pad 9. Repeat steps 1 to 10 to achieve continuous semi-automatic welding production of pad products. Through the automatic grabbing and unloading of the handling robot 4 and the continuous welding operation of the welding robot 7, the continuous semi-automatic production of pad products is achieved. This production method significantly improves production efficiency and reduces manual intervention and waiting time. Combined with automated unloading, it reduces the direct contact of workers with dangerous factors such as high temperature and high pressure, and reduces the risk of work-related accidents.

[0097] From the above description, it can be found that the present invention combines the flexibility of manual work with the efficiency of the automated welding production line to realize the automated welding production of complex structure turnout pad products of various types and full specifications, and improve the welding production efficiency and product quality of turnout pads. The design scheme of the present invention is designed through a semi-automated production method, which can solve the robot automated industrial production of complex category products and provide new ideas for industrial intelligence and automated manufacturing technology.

[0098] It should be understood that although the present specification is described according to an implementation method, the implementation method does not only include an independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in this embodiment can also be appropriately arranged and combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A semi-automatic turnout pad welding production line, characterized by: It includes a host computer, a robot controller (1), a PLC controller (2), and a welding power source (3); It also includes a handling robot (4); the handling robot (4) is arranged at the center of the production line layout; two parallel chain plate conveyor lines (5) are symmetrically arranged on both sides of the handling robot (4), and the handling robot (4) is arranged on the symmetrical center line of the chain plate conveyor line (5); a manual teaming platform (6) is respectively arranged at the starting end of the two chain plate conveyor lines (5), and a welding platform (11) is respectively arranged at the end of the two chain plate conveyor lines (5), and the welding platform (11) is equipped with a welding robot (7); a loading rack (8) is arranged at the symmetrical center line position of the two manual teaming platforms (6); and a finished product material pad (9) is arranged at the symmetrical center line position of the two welding platforms (11).

2. According to the semi-automatic turnout pad welding production line of claim 1, it is characterized by: The handling end of the handling robot (4) is provided with an electromagnetic adsorption extension clamp; the electromagnetic adsorption extension clamp controls the clamp change through the PLC controller (2) and is used to grab the pad bottom plate and complete the pad bottom plate loading and pad finished product unloading.

3. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The chain conveyor line (5) is provided with a position sensor I and a character recognition sensor; the position sensor I is used to detect whether the position of the pad to be welded reaches the pad character recognition detection position; the character recognition sensor is used to identify the characters of the pad to be welded, to determine the type and specification of the pad to be welded, and to upload the character recognition result to the host computer, the host computer processes the character recognition result, and sends instructions to the welding robot (7) and the handling robot (4) through the robot controller (1) to execute the automatic welding program and the automatic unloading program corresponding to the pad character.

4. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The manual teaming platform (6) is provided with a control button I and a status indicator light I; the control button I is used to manually control the loading process of the handling robot (4) and the material transfer process of the chain plate conveyor line (5); the manual teaming platform (6) is provided with a guide bar (61); the guide bar (61) is used to accurately fix the position of the backing plate to be welded near the central axis of the chain plate conveyor line (5).

5. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: A semi-enclosed protective cover (10) is provided on the outside of the welding robot (7); the host computer, the robot controller (1), the PLC controller (2), and the welding power source (3) are arranged on the outside of the protective cover (10) and close to the manual teaming platform (6).

6. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The welding position of the welding platform (11) is provided with a roller (71), a position sensor II (72), a lifting device (73) and a clamping device (74); the roller (71) is used to continuously and smoothly convey the pad to be welded to the welding position of the welding robot (7); after the position sensor II (72) detects that the pad to be welded has reached the specified position, the lifting device (73) lifts and fixes the pad position through the position of the pad bottom plate hole, and the clamping device (74) clamps the pad bottom plate to complete the fixation of the welding operation position of the pad to be welded.

7. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The execution end of the welding robot (7) is provided with a welding assembly; the welding assembly is connected to a welding power source (3), a welding cooling water tank and a shielding gas delivery pipeline; the welding method of the welding robot (7) is metal-metal-shielded gas welding.

8. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The welding robot (7) and the handling robot (4) are both programmed via a teaching pendant.

9. The semi-automatic turnout pad welding production line according to claim 1 is characterized in that: The robot controller (1) is provided with a control button II and a status indicator light II; the control button II is used by operators to shut down the equipment in time in an emergency.

10. A semi-automatic turnout pad welding production method, characterized in that: The production method is a production method using a semi-automatic turnout pad welding production line as claimed in any one of claims 1 to 9, and the production method comprises the following steps: Step 1: Check the power supply; Step 2: Manually control automatic loading; Step 3: Manual pairing; Step 4: Manually control the conveying; Step 5: Character recognition; Step 6: Automatically transport to the welding position; Step 7: Automatically position and fix the pad; Step 8: Automatically weld the backing plate; Step 9: After welding is completed, the clamping device and the lifting device are released; Step 10: Automatic unloading; Repeat steps 1 to 10 to achieve continuous semi-automatic welding production of pad products.

11. The semi-automatic turnout pad welding production method according to claim 10 is characterized in that: In step 1: check and ensure that the equipment, fixtures and various status indicators are working properly, place neatly stacked pallet base plates on the loading rack (8), prepare the pallet assembly positioning template and pallet small parts, and power on the equipment when ready; In step 2: manually press the loading control button I, the handling robot (4) starts to move, and after scanning the palletized pallet bottom plate with 3D vision, it automatically grabs the pallet bottom plate and places it on the manual teaming platform (6); In step 3: with the help of the pad bottom plate assembly positioning template, the pad bottom plate and parts are manually assembled and spot welded; In step 4: manually pressing the chain plate conveyor line start control button I, the chain plate conveyor line (5) starts to run, and one side of the base plate to be welded is brought close to the guide baffle (61), and the base plate to be welded is manually conveyed to the chain plate conveyor line (5); In step 5: when the position sensor I detects that the bottom plate of the pad to be welded has reached the detection position of the character recognition sensor, the chain plate conveyor line (5) stops conveying and the character recognition sensor starts to recognize the character mark of the bottom plate of the pad; In step 6: the character recognition sensor sends the character recognition result to the host computer and the robot controller (1), and after the processing is completed, the chain plate conveyor line (5) starts to operate and conveys the base plate to be welded to the working position of the welding robot (7); In step 7: after the position sensor II (72) of the welding robot (7) detects that the pad bottom plate has reached the designated welding operation position, the lifting device (73) fixes the pad bottom plate position through the pad bottom plate hole position, and the clamping device (74) clamps the pad bottom plate to complete the fixing of the pad to be welded welding operation position; In step 8: the welding robot (7) executes the welding program corresponding to the character mark of the pad and automatically performs pad welding; In step 9: after welding is completed, the clamping device (74) and the lifting device (73) are released; In step 10: the handling robot (4) grabs the finished pad, automatically unloads and places it on the special finished product pad (9).

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