Intelligent automatic welding system for beam-column structure and welding method of intelligent automatic welding system

Abstract

The invention discloses an intelligent automatic welding system for a beam-column structure and a welding method thereof, and relates to the technical field of welding. The invention aims to solve the problems that the adjustment range of the existing welding equipment is limited, so that a workpiece is easy to deviate in the clamping and assembling processes, the controllability of manual operation on the welding process is low, and the dual requirements of large-scale production on speed and precision cannot be met. The automatic welding device comprises a welding robot, a robot controller, a master control system, a positioner and a welding tool, a welding workpiece is clamped on the positioner through the welding tool, the positioner is used for achieving rotation of the welding workpiece, and the welding robot is arranged on one side of the positioner through a linear moving mechanism. The main control system controls the welding poses and welding parameters of the welding robot through the robot controller, and the main control system controls the displacement and moving parameters of the positioner, the welding tool and the linear moving mechanism. The method is used for intelligent automatic welding.

Description

Technical Field

[0001] The present invention relates to the technical field of welding, and in particular to an intelligent automatic welding system for a beam structure and a welding method thereof. Background Art

[0002] In modern industrial manufacturing, with the growing demand for high-performance equipment, welding of complex structural parts such as balance beams and traveling frames has become one of the key process links. The welding quality of these thick-walled metal components directly affects the overall performance, safety and service life of the product. However, traditional welding methods face multiple challenges when dealing with large structural welding tasks, which not only limits the improvement of production efficiency and welding quality, but also leads to energy waste and environmental pollution. These problems are becoming increasingly prominent in the highly competitive manufacturing environment, and an innovative welding solution is urgently needed.

[0003] Traditional welding processes often rely on manual or semi-automatic equipment, especially in the welding of thick-walled butt circumferential seams and long straight longitudinal seams. On the one hand, due to the limited adjustment range of welding equipment, deviations are prone to occur during the clamping and assembly process, resulting in weld dislocation or uneven welding stress. This defect not only reduces the structural strength of the weld, but also increases the repair and scrap rate, affecting the stability of production quality. On the other hand, manual operation has low controllability over the welding process, and it is easy to cause weld inconsistency due to operator fatigue or lack of experience. At the same time, traditional tooling and welding equipment have poor adaptability, and workpieces of different sizes or structures need to be designed separately for corresponding tooling, which not only increases costs, but also limits the flexibility and diversification of production lines. In addition, since welding operations rely on manual judgment and adjustment, efficiency is limited by human factors and cannot meet the dual requirements of speed and precision for large-scale production.

[0004] In terms of environmental protection and energy consumption, traditional welding methods also have problems that cannot be ignored. The large amount of smoke and harmful gases released during welding pose a threat to the health of operators and the working environment, and factories that lack efficient dust removal equipment find it difficult to meet environmental protection standards. At the same time, traditional welding equipment generally consumes a lot of energy, and the material utilization rate during welding is low, especially in terms of welding rework and waste generation, which further increases production costs and waste of resources. These problems not only affect the economic benefits of enterprises, but also increase the burden of environmental governance, which runs counter to the development goals of green manufacturing. Summary of the invention

[0005] In order to solve the problems that the adjustment range of existing welding equipment is limited, which leads to deviations of workpieces during clamping and assembly, the controllability of the welding process by manual operation is low, and the dual requirements of speed and precision for large-scale production cannot be met, the present invention further proposes an intelligent automatic welding system for beam-rod structures and a welding method thereof.

[0006] The technical solution adopted by the present invention to solve the above technical problems is:

[0007] An intelligent automatic welding system for a beam structure includes a welding robot, a robot controller, a master control system, a positioner and a welding fixture. The welding workpiece is clamped on the positioner through the welding fixture. The positioner is used to realize the rotation of the welding workpiece. The welding robot is arranged on one side of the positioner through a linear motion mechanism. The master control system controls the welding posture and welding parameters of the welding robot through the robot controller. The master control system controls the displacement and movement parameters of the positioner, welding fixture and linear motion mechanism.

[0008] Furthermore, the linear motion mechanism includes a welding slide rail and a mounting seat. The welding slide rail is arranged on one side of the positioner. The mounting seat is arranged on the welding slide rail and slides back and forth along the length direction of the welding slide rail through the sliding drive mechanism. The welding robot is fixed to the mounting seat.

[0009] Furthermore, the positioner includes a power head frame, a tail frame, a tail frame slide rail and a base, the power head frame is fixedly connected to one side of the upper end of the base, the tail frame slide rail is fixedly connected to the other side of the upper end of the base, the tail frame is arranged on the tail frame slide rail and slides back and forth along the length direction of the tail frame slide rail through the tail frame driving mechanism.

[0010] Furthermore, the welding tool is matched with the structure of the welding workpiece.

[0011] Furthermore, the welding tooling is used for walking frame welding, and the welding tooling includes an end flange, an end chuck, a holder, a gear spacing adjustment module and two height-adjustable side-end clamping modules. The holder and the end flange are relatively fixed on the positioner. The two height-adjustable side-end clamping modules are relatively arranged on the front end face of the holder through the gear spacing adjustment module. The distance between the two height-adjustable side-end clamping modules is adjustable, and the end chuck is fixed on the front end face of the end flange.

[0012] Furthermore, the gear spacing adjustment module includes a gear spacing slide rail and two connecting seats. The gear spacing slide rail is horizontally arranged on the front end surface of the clamping seat. The two connecting seats are respectively arranged on the gear spacing slide rail and each slides back and forth along the length direction of the gear spacing slide rail through a gear spacing adjustment driving mechanism. Each height-adjustable side end clamping module is respectively fixedly connected to a connecting seat.

[0013] Furthermore, the height-adjustable side-end clamping module includes a vertical slide rail, a side-end flange and a side-end clamping disc. The vertical slide rail is vertically arranged on the connecting seat, the side-end flange is arranged on the vertical slide rail and reciprocates along the length direction of the vertical slide rail through a height adjustment driving mechanism, and the side-end clamping disc is fixedly connected to the inner end face of the side-end flange. The side-end clamping discs of the two height-adjustable side-end clamping modules are arranged relatively to each other.

[0014] Furthermore, the welding tool is used for welding the plug assembly, and the welding tool includes two centering chucks and two centering flanges. The two centering flanges are relatively fixed on the positioner, and each centering chuck is respectively fixed to the front end surface of a centering flange.

[0015] Furthermore, the welding tooling is used for balancing beam welding, and the welding tooling comprises two clamping modules relatively fixed to the positioner, and the clamping module comprises a U-shaped support frame, a hydraulic clamp and a connecting flange, the connecting flange is fixed to the positioner, the U-shaped support frame is fixed to the front end surface of the connecting flange, and the hydraulic clamp is arranged on the open side of the U-shaped support frame and toward the closed side.

[0016] A welding method of an intelligent automatic welding system for a beam structure includes the following processes:

[0017] Welding preparation stage: First, the path planning module in the master control system is used to generate the coordinated motion path of the welding robot, positioner and welding tooling. The path data is transmitted to the robot controller and the control unit of the positioner via real-time Ethernet to ensure that the weld of the welding workpiece is within the working range of the welding robot and consistent with the welding path;

[0018] Welding execution stage: The welding robot performs welding operations along the weld trajectory under the command of the master control system;

[0019] Welding completion stage: The master control system processes the molten pool at the end of the weld through the arc closure and pit filling function.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention proposes a welding motion system and process method based on intelligent design, aiming to comprehensively improve productivity, welding quality and efficiency, while reducing energy consumption and environmental pollution. Through advanced multi-axis linkage robots, precise slide rails and displacement mechanisms, and a highly adaptable tooling system, the present invention not only achieves high-precision control of weld alignment, but also significantly improves the simplicity and consistency of welding operations. With the help of intelligent control systems and digital process packages, parameter adjustment and path optimization during welding can be automated, reducing errors and operational intensity caused by human intervention. In addition, the matching high-efficiency dust removal device further improves the working environment and controls the emission of welding fumes within the limits of environmental protection regulations. Overall, the present invention provides a new solution for the efficient welding of large and complex workpieces through the integration and innovation of technology, laying a technical foundation for the transformation of industrial manufacturing to intelligence and greening.

[0022] Equipment automation and efficient welding: The intelligent automatic welding system of the present invention realizes a high degree of equipment automation. Through the linkage control of the welding robot and the multi-axis motion system, it can automatically complete the welding tasks of push rod and balance beam workpieces. The system can not only flexibly dispatch between multiple workstations, but also automatically adapt to workpieces of different shapes and specifications. The welding robot, through the extended range of motion and precise control system, realizes full automation of welding operations when completing the welding of circumferential seams and long straight longitudinal seams, significantly improving the work efficiency of the production line, reducing human intervention, and improving welding quality and stability.

[0023] Improved efficiency and reduced labor costs: The welding system of the present invention can greatly improve welding speed and work efficiency through multi-station automated operation and intelligent path planning. The introduction of the dual-station operation mode allows one station to complete welding while another station can perform workpiece clamping and spot fixing, thereby reducing idle time and manual intervention. Dynamic adjustment, tooling docking, and path optimization during the welding process are all automated, greatly reducing reliance on manual operation, reducing labor costs, and avoiding welding defects and quality fluctuations caused by human factors.

[0024] Simplify the operation process and reduce the difficulty of getting started: This system adopts an intelligent control system. The operation process of the welding robot and positioner is simplified through an integrated user interface. The operator can set and monitor tasks through an intuitive graphical interface without complex programming and operating skills. This design significantly reduces the difficulty of getting started with the system, allowing operators to master the operation of the equipment after a brief training, effectively reducing training costs. The modular design of the system also makes equipment maintenance and adjustment more convenient, reducing equipment failures and maintenance costs caused by improper operation.

[0025] Precise welding and stability guarantee: The present invention integrates contact positioning sensors, arc length tracking systems and real-time monitoring functions to ensure that every link in the welding process can be precisely controlled. The welding robot can automatically adjust the welding path to ensure that the weld can maintain high quality under any circumstances. The intelligent control system dynamically adjusts relevant parameters through real-time monitoring of the welding arc, workpiece position and welding environment to ensure the stability of welding quality and reduce quality fluctuations caused by human factors.

[0026] Reduce training costs and operational complexity: The system uses an intelligent welding process package, and users can quickly call preset welding parameters according to different workpiece types, eliminating the need for complex process settings and adjustments. The optimization and adjustment of the welding path are completely completed automatically by the system, and the operator only needs to simply confirm and start the welding task, which greatly simplifies the operation process and reduces the requirements for professional skills. Because the operation process is intuitive and simple, the maintenance and adjustment of the equipment also do not require too much professional background, which greatly reduces the training cost.

[0027] Wide applicability and flexibility: This system adopts a highly modular design, which can flexibly adjust the tooling system according to different welding tasks, and adapt to workpieces of different shapes and sizes such as push rods and balance beams. Each tooling solution can be quickly installed and replaced, so that the equipment can not only adapt to current production needs, but also quickly respond to changes in future production tasks. The standardized interface and easy-to-replace design of the tooling system further enhance the versatility of the system and the adaptability of the production line.

[0028] Improve long-term stability and reliability: The invention adopts high-strength materials and precision processing technology, so that the welding equipment can still maintain high stability and reliability during long-term operation. The automatic adjustment function and anti-collision protection mechanism of the equipment effectively avoid the risks brought by equipment damage and operating errors, and ensure the continuous and stable operation of the system in a high-intensity production environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0030] Figure 2 It is a structural schematic diagram of a welding tool when the present invention is used for welding a traveling frame;

[0031] Figure 3 It is a structural schematic diagram of a welding tool when the present invention is used for welding a plug assembly;

[0032] Figure 4 It is a structural schematic diagram of a welding tool when the present invention is used for welding a balance beam. DETAILED DESCRIPTION

[0033] In order to make the technical problems, technical solutions and beneficial effects solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0034] Specific implementation method 1: Combination Figure 1The present embodiment is described. The present embodiment describes an intelligent automatic welding system for a beam structure, which includes a welding robot 2, a robot controller 4, a master control system 5, a positioner 6 and a welding fixture 7. The welding workpiece is clamped on the positioner 6 through the welding fixture 7. The positioner 6 is used to realize the rotation of the welding workpiece. The welding robot 2 is arranged on one side of the positioner 6 through a linear motion mechanism. The master control system 5 controls the welding posture and welding parameters of the welding robot 2 through the robot controller 4. The master control system 5 controls the displacement and movement parameters of the positioner 6, the welding fixture 7 and the linear motion mechanism.

[0035] The welding system can meet the welding requirements of workpieces of various specifications and shapes, and realize efficient and high-precision welding operations.

[0036] The welding robot 2 serves as a core execution unit and has multi-degree-of-freedom motion capabilities for completing the precise execution of the welding trajectory.

[0037] The positioner 6 is used to realize the rotation operation of the workpiece.

[0038] A welding platform 3 is provided on the other side of the welding robot 2 .

[0039] A safety fence 8 is provided on the outside of the system.

[0040] Specific implementation method 2: Combination Figure 1 To illustrate this embodiment, the linear moving mechanism described in this embodiment includes a welding slide rail 1 and a mounting seat. The welding slide rail 1 is arranged on one side of the positioner 6. The mounting seat is arranged on the welding slide rail 1 and reciprocates along the length direction of the welding slide rail 1 through a sliding drive mechanism. The welding robot 2 is fixedly connected to the mounting seat.

[0041] The undisclosed technical features in this embodiment are the same as those in the first embodiment.

[0042] The welding robot 2 is installed on the welding slide rail 1 through a mounting seat, and the range of motion is expanded through the extension design of the welding slide rail 1 to cover multiple workstations. The main body of the welding slide rail 1 is made of high-strength material, and the surface of the welding slide rail 1 is precisely processed to have high straightness and durability. The welding slide rail 1 is fixed to the ground through a ground anchor structure, and horizontal adjustment is achieved through the ground anchor. Flexible shields are installed on both sides of the welding slide rail 1 to prevent welding spatter from entering the slide rail device and affecting the smoothness and accuracy of the operation of the welding slide rail 1. The welding robot 2 is fixed to the mobile platform of the welding slide rail 1 through a modular mounting seat, and the mounting seat includes standardized mounting holes to adapt to different types of welding robots 2. The sliding drive mechanism control system of the welding slide rail 1 is linked with the control system of the welding robot 2, and the linkage system ensures that the relative movement between the robot 2 and the workpiece during welding conforms to the preset welding path.

[0043] In terms of assembly, the modules of the system are assembled through standardized connection interfaces to ensure the stability and modularity of the entire system. The connection between the slide rail and the foundation adopts the ground anchor fixing method. The ground anchor is connected to the foundation through high-strength expansion bolts, and the horizontal correction of the entire slide rail is achieved by adjusting the nut. The guide rail part of the slide rail adopts prefabricated docking grooves, and the grooves are connected by bolts and positioning pins to ensure the straightness and joint tightness between the guide rails.

[0044] The connection between the welding robot 2 and the welding rail 1 adopts a modular mounting seat, which is connected to the bottom of the welding robot 2 by countersunk bolts and base pins to ensure that there is no deviation during the installation process. The welding robot 2 and the mounting seat are connected by high-strength bolts. After the bolts are installed, the torque value is corrected using a torque wrench to avoid installation deviation due to insufficient or over-tightening.

[0045] Specific implementation method three: Combination Figure 1 To illustrate this embodiment, the positioner 6 described in this embodiment includes a power head frame, a tail frame, a tail frame slide rail and a base. The power head frame is fixedly connected to one side of the upper end of the base, the tail frame slide rail is fixedly connected to the other side of the upper end of the base, and the tail frame is arranged on the tail frame slide rail and slides back and forth along the length direction of the tail frame slide rail through the tail frame driving mechanism.

[0046] The undisclosed technical features in this embodiment are the same as those in the first embodiment.

[0047] The power head frame is fixedly mounted on one end of the tailstock slide rail, and the tailstock moves along the tailstock slide rail through the tailstock drive mechanism to adapt to workpieces of different lengths. The straightness of the tailstock slide rail is corrected by adjusting the position of the guide rail fixing base and the horizontal adjustment screw, thereby ensuring the coaxiality between the power head frame and the tailstock. The power head frame and the tailstock are linked by a synchronous control mechanism, and the linkage mechanism is used to ensure the stability and coaxiality of the workpiece rotation. The positioner base is a high-rigidity structure, and a multi-point support device is arranged at the bottom. By adjusting the position and height of the support point, the base can adapt to the ground conditions of different sites, thereby ensuring the stability of the overall structure.

[0048] The power head frame and tail frame of the positioner 6 are connected to the base through the tail frame slide rail, wherein the bottom of the power head frame adopts a flange connection method, and a multi-hole array is provided on the flange for installing bolts, and the uniformity and stability of the connection are improved by diagonal tightening. The tail frame slide rail and the base are fixed by a double-row slider bayonet type, and the slider adopts an adjustable gap design. By adjusting the bayonet compression, the tail frame slide rail and the base are accurately assembled to avoid looseness or excessive jamming that affects the sliding performance.

[0049] Specific implementation method four: Combination Figures 1 to 4 To explain this embodiment, the welding tool 7 described in this embodiment is matched with the structure of the welding workpiece.

[0050] The undisclosed technical features in this embodiment are the same as those in the first embodiment.

[0051] The welding tool 7 provides targeted solutions for various welding requirements, and corresponding clamping modules can be selected according to different shapes and specifications of the workpieces to be welded.

[0052] The welding tool 7 is connected to the positioner 6 through a standardized flange assembly, and a variety of tooling schemes are designed according to the requirements of different welding tasks. Through standardized design, the welding tool 7 realizes flexible replacement and rapid assembly of multiple modules, and different tooling schemes are integrated with the positioner 6 and the welding robot 2 through a universal connection interface, which improves the applicability and welding efficiency of the system.

[0053] Specific implementation method five: Combination Figure 2 To illustrate this embodiment, the welding tool 7 described in this embodiment is used for walking frame welding, and the welding tool 7 includes an end flange 7-1, an end chuck 7-2, a holder 7-3, a gear spacing adjustment module 7-4 and two height-adjustable side end clamping modules 7-5. The holder 7-3 and the end flange 7-1 are relatively fixed to the positioner 6, and the two height-adjustable side end clamping modules 7-5 are relatively arranged on the front end surface of the holder 7-3 through the gear spacing adjustment module 7-4. The distance between the two height-adjustable side end clamping modules 7-5 is adjustable, and the end chuck 7-2 is fixed to the front end surface of the end flange 7-1.

[0054] The undisclosed technical features in this embodiment are the same as those in the fourth embodiment.

[0055] Specific implementation method six: Combination Figure 2 To illustrate this embodiment, the gear spacing adjustment module 7-4 described in this embodiment includes a gear spacing slide rail and two connecting seats. The gear spacing slide rail is horizontally arranged on the front end surface of the clamping seat 7-3, and the two connecting seats are respectively arranged on the gear spacing slide rail and each slides back and forth along the length direction of the gear spacing slide rail through a gear spacing adjustment driving mechanism, and each height-adjustable side end clamping module 7-5 is respectively fixedly connected to a connecting seat.

[0056] The undisclosed technical features in this embodiment are the same as those in the fifth embodiment.

[0057] Specific implementation method seven: Combination Figure 2To illustrate this embodiment, the height-adjustable side-end clamping module 7-5 described in this embodiment includes a vertical slide rail, a side-end flange and a side-end chuck 7-6. The vertical slide rail is vertically arranged on the connecting seat, the side-end flange is arranged on the vertical slide rail and reciprocates along the length direction of the vertical slide rail through a height adjustment driving mechanism, the side-end chuck 7-6 is fixedly connected to the inner end face of the side-end flange, and the side-end chucks 7-6 of the two height-adjustable side-end clamping modules are arranged opposite to each other.

[0058] The undisclosed technical features in this embodiment are the same as those in the sixth embodiment.

[0059] In this embodiment, a special welding tool is designed for the thick-walled butt welding of the traveling frame, aiming to achieve stable clamping of the workpiece and precise alignment of the weld. For the clamping of the cylindrical part, the end chuck 7-2 adopts a three-claw structure, and the clamping force is provided by a spiral mechanism or a hydraulic system to firmly fix the workpiece to be welded, ensuring that no offset or deformation occurs during the clamping process. The end chuck 7-2 is connected to the positioner 6 through the end flange 7-1, and its center hole is coaxial with the rotation axis of the positioner 6, thereby supporting the synchronous rotation of the workpiece during the circumferential seam welding. For the T-shaped part of the traveling frame, the side end chuck 7-6 realizes double-sided clamping and precise positioning through the cooperation of the gear adjustment module 7-4 and the height-adjustable side end clamping module 7-5. The gear adjustment module 7-4 is connected to the card seat 7-3, and the moving range of the gear adjustment module 7-4 can adapt to the clamping requirements of different width parts of the traveling frame. The gear adjustment module 7-4 realizes the alignment of the part to be welded in the horizontal direction through the synchronous movement of the slide rail, thereby ensuring the precise positioning of the weld. The height adjustment module 7-5 is used to adjust the vertical position of the T-shaped part to be welded, and achieves stability and accuracy in the alignment process through a height adjustment drive mechanism, such as a high-precision screw-slide linkage structure.

[0060] In addition to the above-mentioned tooling for the thick-walled butt joint of the walking frame, the system also includes other tooling solutions, such as clamping devices for balance beam components, and special clamping systems for other parts of specific shapes. These tooling systems are based on modular design and are seamlessly integrated with the positioner 6 and the welding robot 2 through standardized connection interfaces such as chucks, slide rails, and flanges to meet a variety of welding needs. In actual applications, various types of tooling are adapted to welding tasks such as circumferential seams and long straight seams through linkage operations with the welding robot 2 and the positioner 6, ensuring high consistency and accuracy of the welding path. By using special tooling systems for different parts, the welding quality and production efficiency are further improved.

[0061] Specific implementation method eight: Combination Figure 3To illustrate this embodiment, the welding tool 7 described in this embodiment is used for welding the plug assembly. The welding tool 7 includes two centering chucks 7-7 and two centering flanges 7-8. The two centering flanges 7-8 are relatively fixed to the positioner 6, and each centering chuck 7-7 is respectively fixed to the front end face of a centering flange 7-8.

[0062] The undisclosed technical features in this embodiment are the same as those in the fourth embodiment.

[0063] Specific implementation method nine: Combination Figure 4 To illustrate this embodiment, the welding tool 7 described in this embodiment is used for balance beam welding. The welding tool 7 includes two clamping modules relatively fixed to the positioner 6. The clamping module includes a U-shaped support frame 7-9, a hydraulic clamp block 7-10 and a connecting flange 7-11. The connecting flange 7-11 is fixed to the positioner 6. The U-shaped support frame 7-9 is fixed to the front end surface of the connecting flange 7-11. The hydraulic clamp block 7-10 is arranged on the open side of the U-shaped support frame 7-9 and is arranged toward the closed side.

[0064] The undisclosed technical features in this embodiment are the same as those in the fourth embodiment.

[0065] Specific implementation method ten: Combination Figures 1 to 4 This embodiment describes a welding method of a beam structure intelligent automatic welding system, which includes the following processes:

[0066] Welding preparation stage: First, the path planning module in the master control system 5 is used to generate the coordinated motion path of the welding robot 2, the positioner 6 and the welding tool 7. The path data is transmitted to the robot controller 4 and the control unit of the positioner 6 via real-time Ethernet to ensure that the weld of the welding workpiece is within the working range of the welding robot 2 and consistent with the welding path;

[0067] Welding execution stage: the welding robot 2 performs welding operations along the weld trajectory under the instruction of the master control system 5;

[0068] Welding completion stage: The master control system 5 processes the molten pool at the end of the weld through the arc closure and pit filling function.

[0069] The software and hardware of the whole system are deeply integrated to achieve intelligent control. The control system consists of the master control system 5 (PC software) and distributed controllers (including robot controller 4 and positioner control unit). The master control system 5 adopts an industrial-grade real-time operating system and is responsible for welding path planning, parameter setting and system status monitoring. The distributed controller communicates with the master control system 5 through the EtherCAT bus to achieve high-speed data transmission and real-time synchronization. The software system includes a welding parameter database and a path optimization module. The former stores a variety of welding process packages, and users can quickly call preset parameters according to the type of workpiece; the latter optimizes the welding path through simulation to reduce motion impact and energy consumption. In terms of hardware, welding sensors, servo drive units and safety monitoring devices are linked through the control system. The welding sensors include arc voltage sensors and contact positioning sensors, which are used for arc length tracking and weld starting point positioning, respectively. The servo drive unit controls the movement of the robot 2, positioner 6 and linear motion mechanism. Its built-in overload protection module automatically cuts off the drive signal when the load exceeds the limit to avoid equipment damage. The safety monitoring device includes an anti-collision sensor and an emergency stop button. The control system can immediately stop all movements when an abnormal signal is detected.

[0070] In the welding preparation stage, the master control system 5 is first used to generate the coordinated motion path of the welding robot 2, the positioner 6 and the welding tool 7. The starting point of the weld is located by contacting the positioning sensor, and the point coordinates are written into the welding path program package pre-stored in the master control system 5 to complete the path planning and calibration work. The forms and shapes of different welds correspond to their respective welding path program packages. In the early stage (for simple welds), the key points of the welding path are taught or (for complex welds) the digital model of the welding path is imported into the path planning software to generate the encapsulated program package of the corresponding path, which is pre-stored in the master control system 5 and selected by the user on the system control panel. In this process, the path planning will comprehensively consider factors such as the smoothness of the welding trajectory, the welding speed, and the quality of the weld to ensure that the generated path meets the requirements of the welding process and maximizes production efficiency.

[0071] The path data is transmitted to the robot controller 4 and the positioner control unit via real-time Ethernet. The controller has multi-axis linkage capability and can coordinate the multi-degree-of-freedom motion of the welding robot 2 and the synchronous rotation motion of the positioner 6 at the same time. At this time, the spacing of the clamping device is adjusted by the spacing adjustment module 7-4 of the welding tool 7 to ensure that the workpiece can be firmly fixed in the tool. The spacing adjustment drive mechanism of the spacing adjustment module 7-4 is driven by a servo motor, and the accuracy of the adjustment is ensured by a built-in position feedback device. Subsequently, the vertical position of the workpiece is fine-tuned using the height adjustment module 7-5, which is driven by a height adjustment drive mechanism such as a screw-gear linkage structure. Its built-in sensor can detect the displacement generated during the adjustment process and automatically correct the deviation through the control system.

[0072] The sensor continuously measures and feeds back the actual height data to the control system, which compares the sensor's measurement results with the preset target position. If a deviation is detected between the actual height and the target height, the control system will calculate the deviation value and issue a corresponding adjustment command by adjusting the drive mechanism. Through the screw-gear linkage structure, the drive mechanism further adjusts the position of the workpiece according to the command of the control system until the actual position is aligned with the target position. This process is a real-time closed-loop control, and the system will continuously correct the position according to the information fed back by the sensor to ensure the accuracy of the adjustment. During the entire height adjustment process, the system can automatically correct any minor deviations caused by installation errors, environmental changes, mechanical movement and welding deformation through real-time detection and dynamic adjustment, thereby ensuring that the workpiece is always in the predetermined precise position. This automatic correction mechanism greatly improves the stability and accuracy of the welding process, reduces manual intervention, and avoids welding defects caused by inaccurate workpiece positioning and welding deformation. The above adjustment ensures that the weld of the workpiece is within the optimal working range of the robot 2 and is highly consistent with the welding path.

[0073] During the welding execution phase, the welding robot 2 performs welding operations along the weld trajectory under the command of the master control system 5. The robot controller 4 receives data fed back by the welding sensor in real time through an integrated multi-task processing module, including contact positioning signals, arc length voltage, welding current and other parameters. The contact positioning function accurately locates the starting position of the weld by detecting the contact point between the welding wire and the workpiece, and dynamically adjusts the starting position of the welding gun using a feedback control algorithm to ensure accurate arc starting. During the welding process, the arc length tracking function collects the welding arc voltage in real time, and these signals show a certain correlation with the arc length. Through real-time analysis of the arc voltage, the control system can determine whether the current arc length meets the set requirements. If the arc voltage deviates from the set value, the control system will automatically calculate the change in arc length and send an adjustment instruction to the welding robot to drive the welding gun to move in the vertical direction, thereby adjusting the distance between the welding gun and the workpiece.

[0074] Since the change in the distance between the welding gun and the workpiece will directly affect the stability of the arc, if the distance is too close, the arc may be too strong and cause welding defects; if the distance is too far, the arc may be too weak and the welding quality will also decrease. Therefore, the control system ensures that the welding gun is always in the optimal position through fine adjustment to maintain a stable arc length. Through this closed-loop feedback mechanism, the arc can be continuously stable during the welding process, thereby ensuring the quality of the weld and avoiding welding defects caused by arc instability. Therefore, by keeping the arc length within the set range, weld defects caused by arc instability can be avoided.

[0075] For the welding of girth welds, the positioner 6 drives the headstock and tailstock to rotate synchronously through a servo motor, and the controller dynamically adjusts the rotation speed according to the change of the welding path to ensure that the running speed of the welding gun on the weld remains consistent. During the welding process of straight welds, the welding robot 2 achieves horizontal movement through the slide rail to expand the working range. The movement of the slide rail is coordinated by the external axis control unit, which receives the linkage command through the communication interface with the robot controller 4. The linkage accuracy between the welding robot 2 body and the linear motion mechanism is monitored by a real-time displacement sensor, and the deviation of the welding path is corrected by an error compensation algorithm.

[0076] At the welding completion stage, the master control system 5 processes the molten pool at the end of the weld through the arc filling function. The master control system 5 will reduce the welding current at the end of welding and extend the welding time to fill the pit at the arc closure to ensure that the weld surface is smooth and free of arc closure cracks. For thick-walled workpieces, the system adopts a multi-layer multi-pass welding process to divide the weld into several layers and complete them layer by layer. During multi-layer welding, after each layer of weld is completed, the master control system 5 dynamically adjusts the current and speed parameters of the next layer of welding through the built-in thermal management module to control the heat input and prevent the weld from overheating and causing deformation.

[0077] The present invention also provides several variations or replacement solutions. For example, the length of the slide rail can be adjusted according to production requirements to adapt to the welding of super-large workpieces; the driving mode of the chuck can be changed to hydraulic or pneumatic to improve the clamping efficiency; the driving system of the height adjustment module and the gear adjustment module can adopt an electric structure to further improve the adjustment accuracy and operation convenience. These variations are all aimed at achieving efficient welding of thick-walled components and provide wide applicability and flexibility.

[0078] Example 1

[0079] This embodiment is suitable for thick-walled butt welding of the traveling frame. The traveling frame workpiece has a cylindrical and T-shaped structure, and has high requirements for the alignment accuracy and welding stability of the weld. Figure 2 As shown, in this embodiment, a set of special welding tooling 7 is designed for the welding of the walking frame. The welding tooling 7 mainly includes an end flange 7-1, an end chuck 7-2, a holder 7-3, a gear adjustment module 7-4 and two height-adjustable side end clamping modules 7-5.

[0080] During the welding preparation stage, the end chuck 7-2 and the side chuck 7-6 in the traveling frame welding fixture 7 provide uniform clamping force through hydraulic drive, clamping the cylindrical part and ensuring that it is coaxial with the welding path. When adjusting the chuck, the operator selects the preset parameters through the control system, and the slide-guided pitch adjustment module 7-4 automatically adjusts the spacing of the side chucks 7-6 according to the specifications of the traveling frame to adapt to the different length requirements of the workpiece. The T-shaped part is supported and clamped by the height adjustment module 7-5, which has a built-in gear-screw linkage device to achieve precise adjustment through the control system. After installation, the sensor on the linear motion mechanism of the welding robot 2 will detect the relative position of the fixture and the workpiece and automatically correct it to ensure the alignment of the weld.

[0081] During the welding process, the power head frame and tail frame of the positioner 6 drive the traveling frame workpiece to rotate synchronously, and the welding robot 2 welds along the weld trajectory according to the path planning. The robot uses the contact positioning and arc length tracking functions to ensure welding accuracy, and the welding parameters such as arc voltage and welding speed are automatically adjusted by the system to adapt to the actual welding state. After welding is completed, the system quickly releases the workpiece through the flange, and the traveling frame maintains high coaxiality and dimensional stability after welding.

[0082] This embodiment realizes efficient and high-precision operation of traveling frame welding through welding tool 7 and automated control, greatly improves welding quality and production efficiency, and simplifies the operation process.

[0083] Example 2

[0084] The plug assembly is a cylindrical structure, and the welding requirements are mainly concentrated at the butt joint annular seam, which has high requirements for the coaxiality and welding stability of the weld. To this end, the present embodiment adopts a centering chuck welding tool 7 to ensure the precise butt joint and clamping of the two parts of the workpiece during the welding process. Figure 3 As shown. In the welding preparation stage, the two parts of the plug assembly workpiece are clamped and fixed by the centering chucks 7-7. Each centering chuck 7-7 adopts a three-claw structure and provides a stable and uniform clamping force through hydraulic drive. The centering chuck 7-7 is installed on the power head frame and tail frame of the positioner 6, and is connected through the centering flange 7-8 to ensure that the center axis of the clamped workpiece remains coaxial with the rotation axis of the positioner 6. The distance between the power head frame and the tail frame can be adjusted by the slide rail according to the length requirements of the plug assembly.

[0085] During the welding process, the welding robot 2 moves to the weld position through the linear moving mechanism and uses the contact positioning function to accurately locate the weld starting point. The welding path planning module generates a circular trajectory according to the circumferential weld welding requirements, and the robot performs welding operations along the weld trajectory. The positioner 6 drives the two centering chucks 7-7 and the plug assembly to rotate through the synchronous control system, and the welding robot 2 keeps the relative position of the welding gun stable to achieve uniform and continuous welding.

[0086] After welding is completed, the workpiece is removed through the quick release mechanism of the tailstock, and the centering chuck 7-7 slide rail is returned to its original position for the next welding operation. The tooling design of this embodiment enables the plug assembly to maintain high coaxiality during welding, effectively avoiding weld deviation, and improving the quality and efficiency of circumferential seam welding.

[0087] Example 3

[0088] The balance beam workpiece is a long strip structure, and the welding needs are concentrated in the center. For this reason, a special balance beam welding tool 7 is used in this embodiment to achieve stable positioning of the workpiece by clamping on both sides, while ensuring that the central welding part is fully exposed. Figure 4 shown.

[0089] During the welding preparation stage, the two ends of the workpiece are fixed by the clamping modules of the tooling. Each clamping module consists of a customized U-shaped support frame 7-9 and a hydraulic clamp block 7-10. The U-shaped support frame 7-9 is used to provide basic support at both ends of the workpiece. The hydraulic clamp block 7-10 applies a uniform clamping force through a hydraulic clamping mechanism to ensure that the workpiece will not deviate or vibrate during the welding process. The clamping module is installed on the power head frame and tail frame of the positioner. The power head frame and tail frame are connected by a high-precision slide rail, and the distance between the two is adjusted according to the length of the workpiece.

[0090] During the welding process, the welding robot moves to the center of the workpiece through a linear motion mechanism and performs welding operations along the center weld. Under the control of the welding path planning module, the robot uses the arc length tracking function to adjust the height of the welding gun in real time to adapt to the slight deformation of the balance beam welding area to ensure consistent weld quality. The power head frame and tail frame maintain the horizontal position of the workpiece through a synchronous control mechanism, allowing the welding robot to complete welding in a stable posture.

[0091] After welding is completed, the system releases the clamping modules at both ends, removes the workpiece, and inspects the welding area. The tooling design of this embodiment ensures that the welding area is fully exposed, and at the same time provides stable support through the clamping on both sides, effectively improving the quality and production efficiency of the balance beam welding.

[0092] Example 4

[0093] This embodiment demonstrates the application of the universal welding platform 3 in the welding of irregular parts. The welding platform 3 is arranged on one side of the welding robot 2. The welding platform 3 is a cast T-slot platform equipped with a standardized clamping module and can be used for the assembly and welding of various non-standard shaped workpieces.

[0094] In the welding preparation stage, according to the shape and size of the workpiece to be welded, the operator adjusts the position and angle of the clamping module on the welding platform 3 so that it fits the specific welding point of the workpiece. Through the flexibility of the T-slot structure, the clamping module can cover multiple welding points within the platform. During the welding process, the welding robot 2 automatically identifies the position of the welding point through the sensor and dynamically adjusts the welding gun posture according to the contour of the workpiece. The rigid design of the welding platform 3 ensures the stability of the workpiece during the welding process and reduces the dimensional deviation caused by welding thermal deformation.

[0095] This embodiment expands the application scope of the system through universal design, can meet the welding requirements of workpieces of different specifications and irregular shapes, and further improves the adaptability of the system.

[0096] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. An intelligent automatic welding system for beam structures, characterized in that: The invention comprises a welding robot (2), a robot controller (4), a master control system (5), a positioner (6) and a welding fixture (7); the welding workpiece is clamped on the positioner (6) by the welding fixture (7); the positioner (6) is used to realize the rotation of the welding workpiece; the welding robot (2) is arranged on one side of the positioner (6) by a linear motion mechanism; the master control system (5) realizes the control of the welding posture and welding parameters of the welding robot (2) by the robot controller (4); and the master control system (5) controls the displacement and movement parameters of the positioner (6), the welding fixture (7) and the linear motion mechanism.

2. According to claim 1, the intelligent automatic welding system for beam structure is characterized in that: The linear motion mechanism comprises a welding slide rail (1) and a mounting seat, wherein the welding slide rail (1) is arranged on one side of a positioner (6), the mounting seat is arranged on the welding slide rail (1) and reciprocates along the length direction of the welding slide rail (1) through a sliding drive mechanism, and the welding robot (2) is fixedly connected to the mounting seat.

3. According to claim 1, the intelligent automatic welding system for beam structure is characterized in that: The positioner (6) comprises a power head frame, a tail frame, a tail frame slide rail and a base, wherein the power head frame is fixedly connected to one side of the upper end of the base, the tail frame slide rail is fixedly connected to the other side of the upper end of the base, and the tail frame is arranged on the tail frame slide rail and reciprocates along the length direction of the tail frame slide rail through a tail frame driving mechanism.

4. According to claim 1, the intelligent automatic welding system for beam structure is characterized in that: The welding tool (7) matches the structure of the welding workpiece.

5. According to claim 4, the intelligent automatic welding system for beam structure is characterized in that: The welding tool (7) is used for welding a traveling frame. The welding tool (7) comprises an end flange (7-1), an end chuck (7-2), a chuck seat (7-3), a gear spacing adjustment module (7-4) and two height-adjustable side end clamping modules (7-5). The chuck seat (7-3) and the end flange (7-1) are relatively fixedly connected to a positioner (6). The two height-adjustable side end clamping modules (7-5) are relatively arranged on the front end surface of the chuck seat (7-3) through the gear spacing adjustment module (7-4). The distance between the two height-adjustable side end clamping modules (7-5) is adjustable. The end chuck (7-2) is fixedly connected to the front end surface of the end flange (7-1).

6. The beam structure intelligent automatic welding system according to claim 5, characterized in that: The gear spacing adjustment module (7-4) comprises a gear spacing slide rail and two connecting seats, the gear spacing slide rail being horizontally arranged on the front end surface of the clamping seat (7-3), the two connecting seats being respectively arranged on the gear spacing slide rail and each sliding back and forth along the length direction of the gear spacing slide rail via a gear spacing adjustment driving mechanism, and each height-adjustable side end clamping module (7-5) being respectively fixedly connected to a connecting seat.

7. The intelligent automatic welding system for beam structure according to claim 6, characterized in that: The height-adjustable side-end clamping module (7-5) comprises a vertical slide rail, a side-end flange and a side-end clamping disc (7-6); the vertical slide rail is vertically arranged on the connecting seat; the side-end flange is arranged on the vertical slide rail and reciprocates along the length direction of the vertical slide rail through a height adjustment driving mechanism; the side-end clamping disc (7-6) is fixedly connected to the inner side end surface of the side-end flange; and the side-end clamping discs (7-6) of the two height-adjustable side-end clamping modules are arranged opposite to each other.

8. The beam structure intelligent automatic welding system according to claim 4, characterized in that: The welding tool (7) is used for welding the plug assembly. The welding tool (7) comprises two centering chucks (7-7) and two centering flanges (7-8). The two centering flanges (7-8) are relatively fixedly connected to the positioner (6). Each centering chuck (7-7) is respectively fixedly connected to the front end surface of a centering flange (7-8).

9. The intelligent automatic welding system for beam structure according to claim 4, characterized in that: The welding tool (7) is used for welding a balance beam. The welding tool (7) comprises two clamping modules relatively fixedly connected to a positioner (6). The clamping modules comprise a U-shaped support frame (7-9), a hydraulic clamping block (7-10) and a connecting flange (7-11). The connecting flange (7-11) is fixedly connected to the positioner (6). The U-shaped support frame (7-9) is fixedly connected to the front end surface of the connecting flange (7-11). The hydraulic clamping block (7-10) is arranged on the open side of the U-shaped support frame (7-9) and is arranged toward the closed side.

10. A welding method according to any one of claims 1 to 9, characterized in that: The method comprises the following steps: Welding preparation stage: first, a path planning module in the master control system (5) is used to generate a coordinated motion path of the welding robot (2), the positioner (6) and the welding tool (7), and the path data is transmitted to the robot controller (4) and the control unit of the positioner (6) via real-time Ethernet to ensure that the weld of the welding workpiece is located within the working range of the welding robot (2) and is consistent with the welding path; Welding execution stage: the welding robot (2) performs welding operations along the weld trajectory under the instruction of the master control system (5); Welding completion stage: The master control system (5) processes the molten pool at the end of the weld through the arc closure and pit filling function.

Images