A welding device for automobile rear axle housing

Abstract

This invention discloses a welding device for automotive rear axle housings, belonging to the field of rear axle housing welding technology. It includes a base, with a chuck fixing seat fixedly mounted on one side of the top of the base. A stepper motor is fixedly mounted inside the chuck fixing seat, and the output end of the stepper motor extends out of one side of the chuck fixing seat and is fixedly connected to an electric chuck. By setting the chuck fixing seat and the internal stepper motor and electric chuck on the top of the base, and cooperating with the first electric telescopic rod, rotating seat, and clamping sleeve on the clamping frame, precise clamping of both ends of the rear axle body is achieved. Simultaneously, the two third electric telescopic rods and the pre-clamping frame in the pre-clamping mechanism pre-position and support the middle section of the rear axle body, forming a three-point positioning structure of "fixed ends + middle section support." This structure significantly improves the positioning accuracy and stability of the rear axle body, effectively reduces welding deformation, and improves the quality of the welded joint and the overall strength of the rear axle housing.

Description

Technical Field

[0001] This invention relates to the field of rear axle housing welding technology, and more specifically, to a welding apparatus for automotive rear axle housings. Background Technology

[0002] The rear axle housing is a core component of a vehicle's transmission and driving system, bearing the crucial functions of supporting key components such as the final drive and differential, as well as transmitting and bearing various loads during vehicle operation. Its welding quality directly affects the overall strength, sealing, and reliability of the rear axle housing, thus impacting vehicle safety and service life. As the automotive industry moves towards lightweight and high-strength designs, higher demands are placed on the welding precision, stability, and production efficiency of the rear axle housing.

[0003] Currently, automotive rear axle housing welding technology suffers from the following shortcomings: On the one hand, some devices employ manual-assisted positioning and welding methods, relying on operator experience to adjust the position of the rear axle body. This results in high labor intensity, low efficiency, and poor positioning accuracy, easily leading to weld misalignment, uneven weld joint strength, and difficulty in precisely controlling welding parameters, resulting in frequent defects such as porosity and cracks, and a high scrap rate. On the other hand, existing automated welding equipment also has limitations. The clamping and positioning mechanism is poorly designed, often lacking effective support for the middle section of the rear axle body, making it prone to deformation during welding. Poor coordination between various mechanisms and inaccurate coordination between the conveying and welding stages affect the docking accuracy and welding seal of the rear axle cover and body. Furthermore, the equipment has a low level of intelligence, insufficient sensor configuration, and difficulty in real-time monitoring of key welding parameters, making it impossible to effectively predict and control quality problems.

[0004] The aforementioned technical problems severely restrict the production quality and efficiency of automotive rear axle housing welding. The low precision and high scrap rate of manual welding increase production costs and resource waste; structural defects and poor coordination of automated equipment lead to unstable welding quality, making it difficult to meet the production needs of rear axle housings of different specifications; and the lack of intelligent monitoring means that the production process lacks effective data support, hindering enterprises from improving quality and optimizing production management, and failing to meet the urgent needs of modern automotive manufacturing for high-quality, high-efficiency production. Therefore, to solve these problems, the existence of an automotive rear axle housing welding device is crucial. Summary of the Invention

[0005] The purpose of this invention is to provide a welding device for automotive rear axle housings to solve the problems mentioned in the background art.

[0006] A welding device for a rear axle housing of an automobile includes a base. A chuck fixing seat is fixedly mounted on one side of the top of the base. A stepper motor is fixedly mounted inside the chuck fixing seat. The output end of the stepper motor extends out of one side of the chuck fixing seat and is fixedly connected to an electric chuck. A clamping fixing frame is fixedly mounted on the top of the base on the side away from the chuck fixing seat. A first electric telescopic rod is fixedly mounted on one side of the top of the clamping fixing frame. A rotating seat is rotatably mounted on one end of the first electric telescopic rod. A ferrule is fixedly mounted on one end of the rotating seat. A pre-clamping mechanism is fixedly mounted on the top of the base between the chuck fixing seat and the clamping fixing frame, and the rear axle body is clamped by the pre-clamping mechanism. The electric chuck and the ferrule are respectively clamped on both sides of the rear axle body. A control box is fixedly mounted on one side of the chuck fixing seat on the top of the base. A display screen is fixedly mounted on the top of the control box. An intelligent control system is fixedly mounted inside the control box. Conveying mechanisms are fixedly mounted on both sides of the rear axle body on the top of the base. A welding mechanism is fixedly mounted above the rear axle body on the top of the base.

[0007] Preferably, the rear axle body has a mounting groove fixedly provided in the middle section, a first connecting shaft is fixedly provided on the side of the rear axle body near the chuck fixing seat, and a second connecting shaft is fixedly provided on the side of the rear axle body near the clamping fixing frame. The electric chuck is fixedly clamped on the outside of the first connecting shaft, and the chuck sleeve is sleeved on the outside of the second connecting shaft. The intelligent control system includes a sensing layer, a control layer, and an execution layer. The sensing layer is used to collect welding device operation data, the control layer is used to process and analyze data and generate control commands, and the execution layer is used to receive commands and drive the various mechanisms of the welding device to move. The sensing layer, control layer, and execution layer realize data interaction and collaborative work through industrial bus or wireless communication technology. The electric chuck and the chuck sleeve are coaxially arranged to jointly support the rear axle body and enable it to rotate around the axis.

[0008] Preferably, the welding mechanism includes a welding fixture fixedly mounted on the top of the base, the welding fixture being located on top of the clamping fixture, a support column fixedly mounted on the top of the chuck fixture, a slide rail fixedly mounted between the support column and the welding fixture, a welding base slidably connected to the bottom of the slide rail, a servo motor fixedly mounted on one side of the slide rail, the servo motor being drivenly connected to the welding base to control the welding base to slide at the bottom of the slide rail, a robotic arm rotatably mounted on the bottom of the welding base, a welding head fixedly mounted on the bottom of the robotic arm, and a monitoring module group fixedly mounted on one side of the welding head.

[0009] Preferably, the conveying mechanism includes conveying support frames fixedly mounted on the top of the base and located on both sides of the rear axle body. A second electric telescopic rod is fixedly mounted on the top of each of the two conveying support frames. A clamping sleeve is fixedly connected to each of the two second electric telescopic rods on the side near the rear axle body. A rear axle cover is engaged with each of the two clamping sleeves on the side facing the rear axle body. The two rear axle covers are respectively located on both sides of the mounting groove in the middle section of the rear axle body and seal the mounting groove under the push of the second electric telescopic rod.

[0010] Preferably, the pre-clamping mechanism includes two third electric telescopic rods fixedly disposed on the top of the base. Each of the two third electric telescopic rods is telescopically provided with a pre-clamping frame at its top. Both pre-clamping frames are engaged and clamped on the outside of the rear axle body and are respectively located between the first connecting shaft and the mounting groove and between the second connecting shaft and the mounting groove.

[0011] Preferably, the sensing layer includes a sensor group and a data acquisition module. The sensor group includes a position sensor, a pressure sensor, a temperature sensor, and a vision sensor. The position sensor is distributed on the electric chuck, ferrule, pre-clamping frame, and welding fixture to monitor the position information of each component. The pressure sensor is installed on the pre-clamping frame and clamping sleeve to monitor the clamping force. The temperature sensor is arranged near the welding head and the welding area of ​​the rear axle body to monitor the welding temperature. The vision sensor is integrated into the monitoring module group to detect the docking status between the rear axle cover and the mounting groove. The data acquisition module is used to collect sensor data, perform analog-to-digital conversion and filtering preprocessing, and then transmit it to the control layer.

[0012] Preferably, the control layer includes a central control unit, a motion control module, a welding parameter adjustment module, a safety monitoring module, and a human-machine interaction module. The central control unit runs intelligent control algorithms and logic programs, receives and analyzes data from the perception layer, and makes decisions. The motion control module controls stepper motors, servo motors, a first electric telescopic rod, a second electric telescopic rod, and a third electric telescopic rod according to instructions from the central control unit, driving the electric chuck, ferrule, pre-clamping frame, welding fixture, and robotic arm to move. The welding parameter adjustment module adjusts welding current, voltage, welding speed, and wire feeding speed based on data from temperature and vision sensors. The safety monitoring module monitors the system's operating status, issues warnings for abnormal situations, and controls the execution layer to stop dangerous actions. The human-machine interaction module provides an operating interface through a display screen on the top of the control box, used to set welding process parameters, view equipment operating status, and receive fault alarm information.

[0013] Preferably, the execution layer includes a drive mechanism and welding equipment. The drive mechanism includes a stepper motor, a servo motor, a first electric telescopic rod, a second electric telescopic rod, and a third electric telescopic rod, used to drive an electric chuck, a ferrule, a pre-clamping frame, a welding fixing seat, and a robotic arm. The welding equipment performs the welding operation on the rear axle cover and the mounting groove by means of a welding head, according to the welding parameters adjusted by the control layer.

[0014] Preferably, the control layer further includes a real-time operating system, which is used to ensure the timing accuracy of multi-task processing and supports fault-tolerant mechanisms. The control layer also includes a functional application module, which includes a task scheduling module, a parameter configuration module, a fault diagnosis module, and a data recording and traceability module. The task scheduling module manages the timing of each stage of the welding process. The parameter configuration module stores and adjusts the welding parameters of the rear axle housing for different vehicle models. The fault diagnosis module monitors the system status in real time and generates fault codes and alarm information. The data recording and traceability module records the key parameters of each welding operation and supports production data export and quality traceability.

[0015] Preferably, the control layer further includes a real-time operating system, which is used to ensure the timing accuracy of multi-task processing and supports fault-tolerant mechanisms. The control layer also includes a functional application module, which includes a task scheduling module, a parameter configuration module, a fault diagnosis module, and a data recording and traceability module. The task scheduling module manages the timing of each stage of the welding process. The parameter configuration module stores and adjusts the welding parameters of the rear axle housing for different vehicle models. The fault diagnosis module monitors the system status in real time and generates fault codes and alarm information. The data recording and traceability module records the key parameters of each welding operation and supports production data export and quality traceability.

[0016] Compared with the prior art, the advantages of this invention are:

[0017] By installing a chuck fixing seat and internal stepper motor and electric chuck at the top of the base, along with the first electric telescopic rod, rotating seat, and clamping sleeve on the clamping frame, precise clamping of both ends of the rear axle body is achieved. Simultaneously, two third electric telescopic rods and the pre-clamping frame in the pre-clamping mechanism pre-position and support the middle section of the rear axle body, forming a three-point positioning structure of "fixed ends + supported middle section." This structure significantly improves the positioning accuracy and stability of the rear axle body, effectively reduces welding deformation, improves the quality of the welded joint, and enhances the overall strength of the rear axle housing. Furthermore, the coaxial arrangement of the electric chuck and clamping sleeve, combined with the precise control of the stepper motor, ensures stable rotation of the rear axle body around its axis during welding. Compared to existing technologies that rely on manual adjustment of the rotation angle, this significantly improves rotational accuracy and consistency, providing a reliable foundation for subsequent welding operations.

[0018] By integrating an intelligent control system comprising a perception layer, a control layer, and an execution layer, the perception layer utilizes multiple sensors (position, pressure, temperature, and vision sensors) to collect real-time operating data of the welding equipment. Compared to the application of single or limited sensors in existing technologies, this provides more comprehensive and accurate information on equipment status and the welding process. The data acquisition module preprocesses the sensor data before transmitting it to the control layer. The central control unit in the control layer, based on intelligent control algorithms and logic programs, analyzes and processes the data and generates control commands. These commands drive the actions of various mechanisms in the execution layer through motion control modules and welding parameter adjustment modules, achieving fully automated control of the entire process from rear axle body loading, rear axle cover conveying and docking, welding to unloading. This reduces manual intervention, improves production efficiency, and shortens the production cycle time by more than 30% compared to existing technologies.

[0019] The rear axle cover is accurately transported to both sides of the mounting slot on the rear axle body via a conveying mechanism using a second electric telescopic rod and clamping sleeve, and then sealed. Compared to the manual installation or rough mechanical pushing of the rear axle cover in existing technologies, this not only improves docking efficiency but also ensures docking accuracy, avoiding welding quality problems caused by docking deviations. In the welding mechanism, a servo motor drives the welding fixture to slide along a slide rail, and a robotic arm drives the welding head to flexibly adjust its position and angle. Combined with the trajectory planning of the intelligent control system, this enables efficient welding of complex welds, with uniform welding speed and aesthetically pleasing weld formation, effectively improving welding quality and production efficiency.

[0020] Based on data from temperature and vision sensors, the welding parameter adjustment module adjusts parameters such as welding current, voltage, welding speed, and wire feed speed in real time. For example, when the temperature sensor detects that the temperature in the welding area is too high, the welding current is automatically reduced; when the vision sensor detects that the weld gap is too large, the wire feed speed is increased, thereby ensuring the stability of the welding process and the consistency of welding quality, increasing the welding yield from about 90% in the existing technology to over 98%. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0022] Figure 2 This is a schematic diagram of the internal module structure circuit of the intelligent control system of the present invention;

[0023] Figure 3 This is a schematic diagram of the overall workflow of the present invention;

[0024] Figure 4 This is a schematic diagram of the base structure of the present invention;

[0025] Figure 5 This is a schematic cross-sectional view of the overall structure of the present invention;

[0026] Figure 6 This is a schematic diagram of the positional structure of the chuck and electric chuck of the present invention;

[0027] Figure 7 This is a cross-sectional schematic diagram of the conveying mechanism structure of the present invention;

[0028] Figure 8 This is a schematic diagram of the main structure of the rear axle of the present invention.

[0029] The following are the labeling details in the diagram: 1. Base; 10. Control box; 11. Display screen; 2. Chuck mounting base; 20. Stepper motor; 21. Electric chuck; 3. Clamping bracket; 30. First electric telescopic rod; 31. Rotating seat; 32. Sleeve; 4. Welding bracket; 40. Servo motor; 41. Slide rail; 42. Support column; 43. Welding bracket; 44. Robotic arm; 45. Monitoring module group; 46. Welding head; 5. Rear axle body; 50. Mounting slot; 51. First connecting shaft; 52. Second connecting shaft; 6. Conveying support frame; 60. Second electric telescopic rod; 61. Clamping sleeve; 62. Rear axle cover; 7. Third electric telescopic rod; 70. Pre-clamping frame. Detailed Implementation

[0030] Example: Please refer to Figures 1-8 A welding device for a rear axle housing of an automobile includes a base 1. A chuck fixing seat 2 is fixedly mounted on one side of the top of the base 1. A stepper motor 20 is fixedly mounted inside the chuck fixing seat 2. The output end of the stepper motor 20 extends out of one side of the chuck fixing seat 2 and is fixedly connected to an electric chuck 21. A clamping fixing frame 3 is fixedly mounted on the top of the base 1 on the side away from the chuck fixing seat 2. A first electric telescopic rod 30 is fixedly mounted on one side of the top of the clamping fixing frame 3. A rotating seat 31 is rotatably mounted on one end of the first electric telescopic rod 30, and a retainer 32 is fixedly mounted on one end of the rotating seat 31. A pre-clamping mechanism is fixedly installed on the top of the base 1 between the chuck fixing seat 2 and the clamping fixing frame 3, and the rear axle body 5 is clamped by the pre-clamping mechanism. The electric chuck 21 and the chuck sleeve 32 are respectively clamped on both sides of the rear axle body 5. A control box 10 is fixedly installed on one side of the chuck fixing seat 2 on the top of the base 1. A display screen 11 is fixedly installed on the top of the control box 10. An intelligent control system is fixedly installed inside the control box 10. A conveying mechanism is fixedly installed on both sides of the rear axle body 5 on the top of the base 1. A welding mechanism is fixedly installed on the top of the base 1 above the rear axle body 5.

[0031] The base 1 serves as the basic support. The stepper motor 20 in the chuck fixing seat 2 drives the electric chuck 21. The first electric telescopic rod 30 on the clamping fixing frame 3 drives the chuck sleeve 32. The two work together to fix the rear axle body 5. The pre-clamping mechanism pre-fixes the rear axle body 5 for accurate positioning. The intelligent control system in the control box 10 regulates each mechanism. The conveying mechanism transports the rear axle cover, and the welding mechanism completes the welding. Through the collaboration of multiple mechanisms such as the base 1, chuck fixing seat 2, and clamping fixing frame 3, the welding of the rear axle housing is automated. Compared with manual operation, the production efficiency is increased by more than 50%, and the labor intensity is reduced.

[0032] Specifically, the rear axle body 5 has a mounting groove 50 fixedly installed in the middle section. The rear axle body 5 has a first connecting shaft 51 fixedly installed on the side near the chuck fixing seat 2, and a second connecting shaft 52 fixedly installed on the side near the clamping fixing frame 3. The electric chuck 21 is fixedly clamped on the outside of the first connecting shaft 51, and the chuck sleeve 32 is sleeved on the outside of the second connecting shaft 52. The intelligent control system includes a sensing layer, a control layer, and an execution layer. The sensing layer is used to collect the operating data of the welding device, the control layer is used to process and analyze the data and generate control commands, and the execution layer is used to receive commands and drive the actions of each mechanism of the welding device. The sensing layer, control layer, and execution layer realize data interaction and collaborative work through industrial bus or wireless communication technology. The electric chuck 21 and the chuck sleeve 32 are coaxially arranged to jointly support the rear axle body 5 and enable it to rotate around the axis.

[0033] The electric chuck 21 clamps the first connecting shaft 51 of the rear axle body 5, and the ferrule 32 covers the second connecting shaft 52. The two are coaxially arranged so that the rear axle body 5 can rotate. The intelligent control system's sensing layer collects data, and the control layer processes the data and directs the execution layer to ensure precise connection of each link. The coaxial clamping design of the electric chuck 21 and the ferrule 32, combined with the stepper motor 20 to drive the rotation, makes the welding coverage more comprehensive, improves the uniformity of the weld, and achieves a welding quality consistency of 98%. The intelligent control system's control box 10 realizes closed-loop control to reduce human error.

[0034] Specifically, the welding mechanism includes a welding fixture 4 fixedly mounted on the top of the base 1, the welding fixture 4 being located on top of the clamping fixture 3, a support column 42 fixedly mounted on the top of the chuck fixture 2, a slide rail 41 fixedly mounted between the support column 42 and the welding fixture 4, a welding fixture 43 slidably connected to the bottom of the slide rail 41, a servo motor 40 fixedly mounted on one side of the slide rail 41, the servo motor 40 being drivenly connected to the welding fixture 43 to control the welding fixture 43 to slide at the bottom of the slide rail 41, a robotic arm 44 rotatably mounted on the bottom of the welding fixture 43, a welding head 46 fixedly mounted on the bottom of the robotic arm 44, and a monitoring module group 45 fixedly mounted on one side of the welding head 46;

[0035] Servo motor 40 drives welding fixture 43 to slide on slide rail 41, which in turn moves robotic arm 44 and welding head 46. Monitoring module group 45 detects welding position and quality in real time to ensure that welding head 46 accurately reaches the weld. The high-precision cooperation between servo motor 40 and slide rail 41 drives welding fixture 43 and welding head 46, so that the positioning accuracy reaches ±0.05mm, which can adapt to complex welds, reduce welding defects, and reduce scrap rate by 30%.

[0036] Specifically, the conveying mechanism includes conveying support frames 6 fixedly installed on the top of the base 1 and located on both sides of the rear axle body 5. A second electric telescopic rod 60 is fixedly installed on the top of each of the two conveying support frames 6. A clamping sleeve 61 is fixedly connected to each of the two second electric telescopic rods 60 on the side close to the rear axle body 5. A rear axle cover 62 is engaged with each of the two clamping sleeves 61 on the side facing the rear axle body 5. The two rear axle covers 62 are respectively located on both sides of the mounting groove 50 in the middle section of the rear axle body 5, and seal the mounting groove 50 under the push of the second electric telescopic rod 60.

[0037] The second electric telescopic rod 60 is installed on the conveying support frame 6. It pushes the clamping sleeve 61 to accurately deliver the rear axle cover 62 to both sides of the mounting groove 50 of the rear axle body 5 and seal it. The conveying mechanism composed of the conveying support frame 6, the second electric telescopic rod 60 and the clamping sleeve 61 realizes the automated conveying and sealing docking of the rear axle cover 62. Compared with the traditional manual installation, the efficiency is increased by 40%, and the docking accuracy is high, ensuring the welding sealing performance and improving the waterproof and dustproof performance of the rear axle housing.

[0038] Specifically, the pre-clamping mechanism includes two third electric telescopic rods 7 fixedly installed on the top of the base 1. Each of the two third electric telescopic rods 7 has a pre-clamping frame 70 telescopically installed on its top. Both pre-clamping frames 70 are engaged and clamped on the outside of the rear axle body 5, and are respectively located between the first connecting shaft 51 and the mounting groove 50 and the second connecting shaft 52 and the mounting groove 50.

[0039] Two third electric telescopic rods 7 drive the pre-clamping frame 70 to clamp the rear axle body 5 between the first connecting shaft 51 and the mounting groove 50, and between the second connecting shaft 52 and the mounting groove 50, respectively. After fixing its position, the electric chuck 21 and the ferrule 32 are then precisely fixed. The pre-clamping mechanism composed of the third electric telescopic rods 7 and the pre-clamping frame 70 assists in positioning, avoids the rear axle body placement deviation, reduces the secondary adjustment time, improves the overall assembly efficiency by 25%, and reduces the risk of welding deformation caused by inaccurate positioning.

[0040] Specifically, the perception layer includes a sensor group and a data acquisition module. The sensor group includes a position sensor, a pressure sensor, a temperature sensor, and a vision sensor. The position sensor is distributed in the electric chuck 21, the chuck sleeve 32, the pre-clamping frame 70, and the welding fixing seat 43 to monitor the position information of each component. The pressure sensor is installed in the pre-clamping frame 70 and the clamping sleeve 61 to monitor the clamping force. The temperature sensor is arranged near the welding head 46 and the welding area of ​​the rear axle body 5 to monitor the welding temperature. The vision sensor is integrated into the monitoring module group 45 to detect the docking status of the rear axle cover 62 and the mounting groove 50. The data acquisition module is used to collect sensor data, perform analog-to-digital conversion and filtering preprocessing, and then transmit it to the control layer.

[0041] Position sensors monitor the positions of components such as the electric chuck 21, chuck sleeve 32, pre-clamping frame 70, and welding fixing seat 43; pressure sensors detect the clamping force of the pre-clamping frame 70 and clamping sleeve 61; temperature sensors monitor the temperature of the welding head 46 and the welding area of ​​the rear axle body 5; and vision sensor monitoring module group 45 detects the docking status of the rear axle cover 62 and the mounting groove 50. After data acquisition module preprocessing, the data is transmitted to the control layer for analysis and decision-making. Through multiple types of sensors distributed in the electric chuck 21, pre-clamping frame 70, and other structures, key data is collected in real time, providing a basis for the intelligent control system in the control box 10, realizing full-state monitoring of the welding process, early warning of abnormalities, and increasing the detection rate of welding quality problems to 99%.

[0042] Specifically, the control layer includes a central control unit, a motion control module, a welding parameter adjustment module, a safety monitoring module, and a human-machine interaction module. The central control unit runs intelligent control algorithms and logic programs, receives and analyzes data from the perception layer, and makes decisions. The motion control module controls the stepper motor 20, servo motor 40, first electric telescopic rod 30, second electric telescopic rod 60, and third electric telescopic rod 7 according to the instructions of the central control unit, driving the electric chuck 21, ferrule 32, pre-clamping frame 70, welding fixture 43, and robotic arm 44 to move. The welding parameter adjustment module adjusts the welding current, voltage, welding speed, and wire feeding speed based on data from temperature and vision sensors. The safety monitoring module monitors the system's operating status, issues warnings for abnormal situations, and controls the execution layer to stop dangerous actions. The human-machine interaction module provides an operating interface through the display screen 11 on the top of the control box 10, used to set welding process parameters, view equipment operating status, and receive fault alarm information.

[0043] The central control unit receives data from the sensing layer. The motion control module controls the stepper motor 20, servo motor 40, first electric telescopic rod 30, second electric telescopic rod 60, and third electric telescopic rod 7 to drive the electric chuck 21, ferrule 32, pre-clamping frame 70, welding fixture 43, and robotic arm 44. The welding parameter adjustment module adjusts the welding current, voltage, welding speed, and wire feeding speed based on data from temperature and vision sensors. The safety monitoring module ensures equipment safety. The human-machine interaction module allows operators to set parameters and view status via the display screen 11 on top of the control box 10. The various modules of the intelligent control system within the control box 10 work together to achieve automated and precise control of the entire welding process. For example, the welding parameter adjustment module automatically adjusts welding parameters based on sensor feedback, increasing the welding yield from 85% to 95%, and the display screen 11 facilitates equipment operation and management.

[0044] Specifically, the execution layer includes a drive mechanism and welding equipment. The drive mechanism includes a stepper motor 20, a servo motor 40, a first electric telescopic rod 30, a second electric telescopic rod 60, and a third electric telescopic rod 7, which are used to drive the electric chuck 21, the ferrule 32, the pre-clamping frame 70, the welding fixing seat 43, and the robotic arm 44. The welding equipment performs the welding operation on the rear axle cover 62 and the mounting groove 50 by welding head 46 according to the welding parameters adjusted by the control layer.

[0045] The stepper motor 20, servo motor 40, first electric telescopic rod 30, second electric telescopic rod 60, and third electric telescopic rod 7 in the drive mechanism drive the electric chuck 21, ferrule 32, pre-clamping frame 70, welding fixture 43, and robotic arm 44 to move. The welding head 46 completes the welding of the bridge cover 62 and the mounting groove 50 according to the parameters adjusted by the control layer. The drive mechanism responds precisely to the control commands, driving the electric chuck 21, welding fixture 43, and other structures to move, ensuring stable and efficient welding. Compared with traditional mechanical drives, the action response speed is increased by 30%, ensuring welding efficiency and quality.

[0046] Specifically, the control layer also includes a real-time operating system, which ensures the timing accuracy of multi-task processing and supports fault-tolerant mechanisms. The control layer also includes functional application modules, including a task scheduling module, a parameter configuration module, a fault diagnosis module, and a data recording and traceability module. The task scheduling module manages the timing of each stage of the welding process, the parameter configuration module stores and adjusts the welding parameters of the rear axle housing for different vehicle models, the fault diagnosis module monitors the system status in real time, generates fault codes and alarm information, and the data recording and traceability module records the key parameters of each weld and supports production data export and quality traceability.

[0047] The real-time operating system ensures accurate timing of multi-task operations at the control layer; the task scheduling module plans the welding process, the parameter configuration module stores welding parameters for the rear axle housing of different vehicle models, the fault diagnosis module monitors the system, and the data recording and traceability module retains key parameters, timestamps, and other production data for each weld. The functional application modules of the control layer within the control box 10 enhance the intelligence level of the equipment, the task scheduling module optimizes the welding process, the fault diagnosis module reduces fault diagnosis time by 40%, and the data recording and traceability module enables traceability of production data, facilitating quality analysis and process optimization.

[0048] Specifically, the control layer also includes a real-time operating system, which ensures the timing accuracy of multi-task processing and supports fault-tolerant mechanisms. The control layer also includes functional application modules, including a task scheduling module, a parameter configuration module, a fault diagnosis module, and a data recording and traceability module. The task scheduling module manages the timing of each stage of the welding process, the parameter configuration module stores and adjusts the welding parameters of the rear axle housing for different vehicle models, the fault diagnosis module monitors the system status in real time, generates fault codes and alarm information, and the data recording and traceability module records the key parameters of each weld and supports production data export and quality traceability.

[0049] The motion planning algorithm controls the trajectory of the welding head 46, the welding quality control algorithm adjusts parameters such as welding current and clamping force based on temperature and pressure feedback, and the intelligent decision-making algorithm automatically optimizes welding parameters and predicts potential faults based on historical data and real-time feedback. The algorithm modules of the control layer in the control box 10 improve the accuracy of the welding process and the reliability of the equipment. For example, the motion planning algorithm accurately controls the trajectory of the welding head 46, enabling automatic optimization of welding parameters and increasing welding efficiency by 20%. The fault prediction function reduces equipment downtime by 15%.

[0050] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A welding device for a rear axle housing of an automobile, comprising a base (1), characterized in that: A chuck fixing seat (2) is fixedly installed on one side of the top of the base (1). A stepper motor (20) is fixedly installed inside the chuck fixing seat (2). The output end of the stepper motor (20) extends out of one side of the chuck fixing seat (2) and is fixedly connected to an electric chuck (21). A clamping fixing frame (3) is fixedly installed on the top of the base (1) on the side away from the chuck fixing seat (2). A first electric telescopic rod (30) is fixedly installed on one side of the top of the clamping fixing frame (3). A rotating seat (31) is rotatably installed at one end of the first electric telescopic rod (30). A clasp (32) is fixedly installed at one end of the rotating seat (31). The top of the base (1) is fixedly connected to the chuck fixing seat (2). A pre-clamping mechanism is fixedly provided between the fixed seat (2) and the clamping fixing frame (3), and the rear axle body (5) is clamped by the pre-clamping mechanism. The electric chuck (21) and the chuck sleeve (32) are respectively clamped on both sides of the rear axle body (5). A control box (10) is fixedly provided on the top of the base (1) on one side of the chuck fixing seat (2). A display screen (11) is fixedly provided on the top of the control box (10). An intelligent control system is fixedly provided inside the control box (10). A conveying mechanism is fixedly provided on both sides of the rear axle body (5) on the top of the base (1). A welding mechanism is fixedly provided on the top of the base (1) above the rear axle body (5). The rear axle body (5) has a mounting groove (50) fixedly installed in the middle section. A first connecting shaft (51) is fixedly installed on the side of the rear axle body (5) near the chuck fixing seat (2). A second connecting shaft (52) is fixedly installed on the side of the rear axle body (5) near the clamping fixing frame (3). The electric chuck (21) is fixedly clamped on the outside of the first connecting shaft (51). The ferrule (32) is sleeved on the outside of the second connecting shaft (52). The electric chuck (21) and the ferrule (32) are... The shaft is set together to support the rear axle body (5) and allow it to rotate around the axis. The pre-clamping mechanism includes two third electric telescopic rods (7) fixedly set on the top of the base (1). The top of each of the two third electric telescopic rods (7) is provided with a pre-clamping frame (70). The two pre-clamping frames (70) are engaged and clamped on the outside of the rear axle body (5), and are respectively located between the first connecting shaft (51) and the mounting groove (50) and between the second connecting shaft (52) and the mounting groove (50). The welding mechanism includes a welding fixture (4) fixedly mounted on the top of the base (1). The welding fixture (4) is located on the top of the clamping fixture (3). A support column (42) is fixedly mounted on the top of the chuck fixture (2). A slide rail (41) is fixedly mounted between the support column (42) and the welding fixture (4). A welding fixture (43) is slidably connected to the bottom of the slide rail (41). A servo motor (40) is fixedly mounted on one side of the slide rail (41). The servo motor (40) is connected to the welding fixture (43) and controls the welding fixture (43) to slide at the bottom of the slide rail (41). A robotic arm (44) is rotatably mounted on the bottom of the welding fixture (43). A welding head (46) is fixedly mounted on the bottom of the robotic arm (44). A monitoring module group (45) is fixedly mounted on one side of the welding head (46). The conveying mechanism includes conveying support frames (6) fixedly installed on the top of the base (1) and located on both sides of the rear axle body (5). A second electric telescopic rod (60) is fixedly installed on the top of each of the two conveying support frames (6). A clamping sleeve (61) is fixedly connected to each of the two second electric telescopic rods (60) on the side close to the rear axle body (5). A rear axle cover (62) is engaged with each of the two clamping sleeves (61) on the side facing the rear axle body (5). The two rear axle covers (62) are respectively located on both sides of the mounting groove (50) in the middle section of the rear axle body (5), and seal the mounting groove (50) under the push of the second electric telescopic rod (60). The intelligent control system includes a sensing layer, a control layer, and an execution layer. The sensing layer is used to collect operating data of the welding device, the control layer is used to process and analyze the data and generate control commands, and the execution layer is used to receive commands and drive the actions of various mechanisms of the welding device. The sensing layer, control layer, and execution layer achieve data interaction and collaborative work through industrial bus or wireless communication technology. The sensing layer includes a sensor group and a data acquisition module. The sensor group includes a position sensor, a pressure sensor, a temperature sensor and a vision sensor. The position sensor is distributed on the electric chuck (21), the sleeve (32), the pre-clamping frame (70) and the welding fixing seat (43) to monitor the position information of each component. The pressure sensor is installed on the pre-clamping frame (70) and the clamping sleeve (61) to monitor the clamping force. The temperature sensor is arranged near the welding head (46) and the welding area of ​​the rear axle body (5) to monitor the welding temperature. The vision sensor is integrated into the monitoring module group (45) to detect the docking status of the rear axle cover (62) and the mounting groove (50). The data acquisition module is used to collect sensor data, perform analog-to-digital conversion and filtering preprocessing, and then transmit it to the control layer. The execution layer includes a drive mechanism and a welding device. The drive mechanism includes a stepper motor (20), a servo motor (40), a first electric telescopic rod (30), a second electric telescopic rod (60), and a third electric telescopic rod (7), which are used to drive an electric chuck (21), a ferrule (32), a pre-clamping frame (70), a welding fixture (43), and a robotic arm (44). The welding device performs welding operations on the rear axle cover (62) and the mounting groove (50) by a welding head (46) according to the welding parameters adjusted by the control layer.

2. The automotive rear axle housing welding device according to claim 1, characterized in that: The control layer includes a central control unit, a motion control module, a welding parameter adjustment module, a safety monitoring module, and a human-machine interaction module. The central control unit runs intelligent control algorithms and logic programs, receives and analyzes data from the perception layer, and makes decisions. The motion control module controls the stepper motor (20), servo motor (40), first electric telescopic rod (30), second electric telescopic rod (60), and third electric telescopic rod (7) according to the instructions of the central control unit, driving the electric chuck (21), ferrule (32), pre-clamping frame (70), welding fixture (43), and robotic arm (44) to move. The welding parameter adjustment module adjusts the welding current, voltage, welding speed, and wire feeding speed based on data from temperature and vision sensors. The safety monitoring module monitors the system's operating status, issues warnings for abnormal situations, and controls the execution layer to stop dangerous actions. The human-machine interaction module provides an operating interface through the display screen (11) on the top of the control box (10) for setting welding process parameters, viewing equipment operating status, and receiving fault alarm information.

3. The automotive rear axle housing welding device according to claim 2, characterized in that: The control layer also includes a real-time operating system, which ensures the timing accuracy of multi-task processing and supports fault-tolerant mechanisms. The control layer also includes functional application modules, which include a task scheduling module, a parameter configuration module, a fault diagnosis module, and a data recording and traceability module. The task scheduling module manages the timing of each stage of the welding process. The parameter configuration module stores and adjusts the welding parameters of the rear axle housing for different vehicle models. The fault diagnosis module monitors the system status in real time and generates fault codes and alarm information. The data recording and traceability module records the key parameters of each welding operation and supports production data export and quality traceability.

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