An electrical control system and parallel scheduling method for a large gear automatic welding workstation

Abstract

The application provides an electrical control system and parallel scheduling method of a large gear automatic welding workstation, belongs to the field of automatic welding equipment and intelligent manufacturing technology, the method controls two riveting and welding platforms to alternately perform welding, turning over and feeding and discharging through a central controller, and realizes no-waiting alternate operation by using area interlocking and pre-switching logic; combined with demonstration-free visual guidance welding and mobile base control, it ensures continuous operation of the welding robot and guarantees that multiple mobile work equipment do not interfere and collide; the central controller opens an industrial Ethernet protocol interface, collects welding parameters in real time and uploads them to an MES system, realizes data tracing and remote monitoring. The application solves the problems of low utilization rate, weak multi-variety adaptability, weak collaborative control ability and insufficient data collection and networking ability of the existing large gear welding workstation equipment.

Description

Technical Field

[0001] This invention belongs to the field of automated welding equipment and intelligent manufacturing technology, specifically relating to an electrical control system and parallel scheduling method for a large gear automatic welding workstation. Background Technology

[0002] Large gears are core transmission components of heavy equipment such as presses, and their welding process involves a large number of bevel welds, fillet welds, and multi-layer, multi-pass welding. Existing welding workstations typically adopt a single-station layout: the workpiece is manually hoisted onto the welding platform, the welding robot is taught and programmed before welding, and after welding is completed, it is manually flipped or a simple positioner is used to continue welding. This approach has many drawbacks: First, equipment utilization is low: when the welding robot is welding, the positioner and loading / unloading platform are idle, and the entire workstation is shut down during manual loading and unloading, with the robot's actual working time usually less than 50%. Second, for gear workpieces with multiple varieties and small batches, manual teaching and programming are required for each workpiece change, resulting in long preparation time and making it unsuitable for rapid production changeovers. Even if some workstations are equipped with laser weld seam tracking systems to correct trajectories in real time, manual teaching is still required to complete the initial path setting, which cannot solve the problem of production changeover efficiency. In addition, the riveting and welding platform, flipping positioner, and other working equipment share a limited space, lacking unified scheduling logic and area interlocking, which easily leads to interference and collisions. Finally, welding equipment mostly operates in isolation, and data such as welding parameters, equipment status, and energy consumption cannot be collected and uploaded to the MES system in real time, making it difficult to meet the requirements of a digital workshop.

[0003] In view of this, it is very necessary to provide an electrical control system and parallel scheduling method for a large-scale automatic gear welding workstation to solve the above-mentioned defects in the prior art. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of the existing technology, such as low equipment utilization, weak adaptability to various product types, weak collaborative control capabilities, and insufficient data acquisition and networking capabilities, by providing an electrical control system and parallel scheduling method for a large-scale automatic gear welding workstation to solve the aforementioned technical problems.

[0005] In a first aspect, embodiments of this application provide an electrical control system for a large-scale automatic gear welding workstation, including: a welding robot, a flipping and positioning machine, a first riveting and welding platform, a second riveting and welding platform, and a central controller; The welding robot is located at the welding station, and the flipping and positioning machine is located at the flipping station; the first riveting and welding platform is located at the first loading station, and the second riveting and welding platform is located at the second loading station; the central controller has a built-in dual-station parallel scheduling state machine.

[0006] Furthermore, the dual-station parallel scheduling state machine includes: state variables of the first riveting and welding platform and the second riveting and welding platform; the state variables include at least: idle state, centering state, heading to welding position state, welding in progress state, heading to flipping position state, flipping in progress state, and return state.

[0007] Furthermore, both the first and second riveting platforms are equipped with a movable base and a centering clamp; The movable base is used to carry the workpiece and drive the workpiece to move between the first loading station, the second loading station, the welding station and the flipping station; The centering fixture is used to perform a loosening action during the centering process to release the thermal deformation stress generated in the workpiece during welding; the centering fixture is also used to perform a clamping action when transporting to the flipped position or the return position to fix the workpiece and prevent the workpiece from shifting during transportation.

[0008] Secondly, embodiments of this application also provide a parallel scheduling method for electrical control of a large-scale automatic gear welding workstation, comprising the following steps: Step S1: After the first riveting and welding platform completes the workpiece hoisting and centering at the first loading station, the central controller controls the moving base of the first riveting and welding platform to move towards the welding station. Step S2: After the first riveting and welding platform arrives at the welding station, it notifies the welding robot to start welding. At the same time, the second riveting and welding platform centers the next workpiece at the second loading station, and the central controller applies area interlock to the second riveting and welding platform. Step S3: After the welding robot completes the welding of one side of the current workpiece, the central controller switches the state to the transport to the flipping position state and controls the moving base of the first riveting and welding platform to transport the workpiece to the flipping position, and notifies the flipping positioner to perform the flipping action; after the flipping action is completed, the central controller controls the first riveting and welding platform to transport the workpiece back to the welding position and continue welding the other side. Step S4: When the first riveting and welding platform completes all welding tasks, the state switches to the return state; the central controller reads the state variables of the second riveting and welding platform: if the second riveting and welding platform has completed alignment and is in an idle state, then the pre-switching logic is executed; In step S5, the second riveting and welding platform performs the welding, flipping, and return process of the next workpiece according to steps S2 to S4; at the same time, after the first riveting and welding platform returns to the first loading station, it switches to an idle state to allow the next workpiece to be loaded. Step S6: Repeat steps S2 to S5 until all workpieces are welded.

[0009] Furthermore, the area interlocking in step S2 employs an area interlocking matrix built into the central controller, specifically including: Define the mutual exclusion relationships between the equipment in the four areas: welding station, flipping station, first loading station, and second loading station; Based on the mutual exclusion relationship of the equipment, when the first riveting and welding platform is in the welding station or the flipping station, the moving base of the second riveting and welding platform is prohibited from moving to the welding station or the flipping station, while the second riveting and welding platform is allowed to perform centering operation at the second loading station.

[0010] Furthermore, the aforementioned equipment mutual exclusion relationship specifically includes: mutual exclusion between the welding station and the flipping station: at any given time, only the first riveting and welding platform or the second riveting and welding platform is allowed to enter the welding station or the flipping station alone; when either riveting and welding platform occupies the welding station or the flipping station, the central controller locks the moving base drive signal of the other riveting and welding platform through the area interlock matrix.

[0011] Furthermore, in step S2, the welding robot welding process adopts a teach-free welding control method, specifically including: The central controller triggers the built-in vision controller of the welding robot to execute scanning instructions via the Modbus TCP protocol, performing 3D visual modeling of the current workpiece and generating planned welding paths and process parameters; The signal indicating the completion of the modeling is returned to the central controller. At the same time, the planned welding path and process parameters are sent to the welding robot's welding controller via Ethernet. After confirming that the modeling is complete, the central controller notifies the welding robot to start the welding program, ensuring that each weld seam is scanned before welding. During the welding process, the central controller collects welding parameters in real time and transmits the data to the workshop's MES system via industrial Ethernet. The workshop's laser weld seam tracking system calculates the deviation between the actual weld seam trajectory and the planned welding path to correct the welding trajectory.

[0012] Furthermore, during the welding process, the central controller collects welding parameters in real time and transmits the data to the workshop MES system via industrial Ethernet, specifically including: The central controller collects welding parameters in real time. These welding parameters include at least: weld position information, welding voltage, welding current, welding speed, welding time, welding wire consumption, instantaneous gas flow rate and cumulative consumption, workstation energy consumption, and equipment fault codes. The central controller has an open industrial Ethernet protocol interface, which connects to the workshop MES system via Ethernet, uploads the welding parameters to the MES system, and receives remote order tasks and process parameters issued by the MES system.

[0013] Furthermore, in steps S1 and S3, the central controller controls the movement of the mobile base, specifically including: The central controller controls the moving base of the first or second riveting platform to move at a set speed via a servo driver; a positioning detection sensor is installed on the moving base's path to send a positioning signal to the central controller when the moving base reaches the target workstation, and the central controller responds to the positioning signal to control the servo driver to decelerate and stop.

[0014] Furthermore, the pre-switching logic in step S4 includes: The central controller controls the first riveting and welding platform to return from the welding station to the first loading station; Start the second riveting and welding platform and move it towards the welding station; The time interval between the first riveting and welding platform completely exiting the welding station boundary and the second riveting and welding platform starting to enter the welding station boundary shall not exceed 2 seconds.

[0015] As can be seen from the above technical solutions, the present invention has the following advantages: By integrating a dual-station parallel scheduling state machine and regional interlocking matrix into the central controller, the two riveting and welding platforms can perform alternating operations without waiting between welding, flipping, and loading / unloading processes, allowing the welding robot to run continuously and improving equipment utilization. Through direct communication between the teachless vision controller and the robot controller, a welding production process of scanning and modeling, planning, and welding is constructed. It can automatically identify weld features and generate planned welding paths and process parameters without manual teaching. Combined with laser weld tracking for real-time trajectory correction, it can adapt to the rapid changeover requirements of various gears. Through the coordinated control of servo drives and position detection, superimposed with regional mutual exclusion logic, it ensures that multiple moving working devices do not interfere or collide, improving equipment collaborative control capabilities. The central controller provides open OPC UA and Modbus TCP protocol interfaces to collect welding parameters in real time and upload them to the MES system, enabling data traceability and remote monitoring, and solving the problem of equipment data silos. Attached Figure Description

[0016] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart of a parallel scheduling method for electrical control of a large-scale automatic gear welding workstation.

[0018] Figure 2 This is a schematic diagram of the electrical control system of a large-scale automatic gear welding workstation. Detailed Implementation

[0019] The specific steps of the parallel scheduling method for the electrical control of a large gear automatic welding workstation will be described in detail below, providing a more comprehensive description of various embodiments of this disclosure. This disclosure may have various embodiments, and adjustments and changes may be made therein. However, it should be understood that there is no intention to limit the various embodiments of this disclosure to the specific embodiments disclosed herein, but rather this disclosure should be understood to cover all adjustments, equivalents, and / or alternatives falling within the spirit and scope of the various embodiments of this disclosure.

[0020] This embodiment provides an electrical control parallel scheduling method for a large-scale automatic gear welding workstation. The central controller controls two riveting and welding platforms to alternately perform welding, flipping, and loading / unloading. Regional interlocking and pre-switching logic are used to achieve alternating operations without waiting, thereby improving equipment utilization and production speed.

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1 The diagram illustrates a parallel scheduling method for the electrical control of a large-scale automatic gear welding workstation, comprising the following steps: Step S1: After the first riveting and welding platform completes the workpiece hoisting and centering at the first loading station, the central controller controls the moving base of the first riveting and welding platform to move towards the welding station. It should be noted that the central controller automatically triggers the first riveting and welding platform to move to the welding station, realizing automatic transfer without manual intervention after the material is loaded. This shortens the waiting time from loading to welding and improves the smoothness of process connection.

[0023] Step S2: After the first riveting and welding platform arrives at the welding station, it notifies the welding robot to start welding. At the same time, the second riveting and welding platform centers the next workpiece at the second loading station, and the central controller applies area interlock to the second riveting and welding platform. It should be noted that by having the welding robot and the second riveting platform perform welding and centering operations respectively, the welding and material loading processes can be carried out in parallel. At the same time, an area interlock is applied to the second platform to ensure that it will not accidentally enter the welding station during the welding process, thus ensuring equipment safety under parallel operation.

[0024] Step S3: After the welding robot completes the welding of one side of the current workpiece, the central controller switches the state to the transport to the flipping position state and controls the moving base of the first riveting and welding platform to transport the workpiece to the flipping position, and notifies the flipping positioner to perform the flipping action; after the flipping action is completed, the central controller controls the first riveting and welding platform to transport the workpiece back to the welding position and continue welding the other side. It should be noted that by using a central controller to uniformly schedule the first riveting and welding platform and the flipping and positioning machine to complete the flipping action, the automated flow of double-sided welding of workpieces is realized. The flipping is done without manual intervention, which ensures welding continuity and operational safety.

[0025] Step S4: When the first riveting and welding platform completes all welding tasks, the state switches to the return state; the central controller reads the state variables of the second riveting and welding platform: if the second riveting and welding platform has completed alignment and is in an idle state, then the pre-switching logic is executed; It should be noted that by reading the status of the second platform in advance when the welding task is completed on the first platform, and executing the pre-switching logic when the conditions are met, the second platform can start moving towards the welding station as soon as the first platform returns, thus reducing the idle waiting time of the welding station.

[0026] In step S5, the second riveting and welding platform performs the welding, flipping, and return process of the next workpiece according to steps S2 to S4; at the same time, after the first riveting and welding platform returns to the first loading station, it switches to an idle state to allow the next workpiece to be loaded. It should be noted that while the welding process is continued through the second platform, the first platform returns to the loading station and switches to an idle state, realizing a seamless alternation of roles between the two platforms, enabling the welding robot to operate continuously and maximizing equipment utilization.

[0027] Step S6: Repeat steps S2 to S5 until all workpieces are welded. It should be noted that by repeatedly executing the above parallel scheduling process until all workpieces are welded, the automated cyclic operation of the welding robot in batch production scenarios is realized, ensuring the efficiency and stability of continuous welding of multiple workpieces.

[0028] This embodiment achieves seamless alternating operation between two riveting and welding platforms through parallel scheduling of dual workstations, combined with regional interlocking and pre-switching logic. By combining teachless vision-guided welding with closed-loop control of the moving base, it ensures continuous operation of the welding robot and guarantees no collision risk for multiple working devices, thus solving the problems of low utilization rate and weak collaborative control of large gear welding equipment.

[0029] Furthermore, as a refinement and extension of the specific implementation of the above embodiments, in order to fully illustrate the specific implementation process in this embodiment, another parallel scheduling method for electrical control of a large-scale automatic gear welding workstation is provided, which includes the following steps: Step S1: After the first riveting and welding platform completes the workpiece hoisting and centering at the first loading station, the central controller controls the moving base of the first riveting and welding platform to move towards the welding station. Step S2: After the first riveting and welding platform arrives at the welding station, it notifies the welding robot to start welding. At the same time, the second riveting and welding platform centers the next workpiece at the second loading station, and the central controller applies area interlock to the second riveting and welding platform. The area interlocking in step S2 uses the area interlocking matrix built into the central controller, specifically including: Define the mutual exclusion relationships between the equipment in the four areas: welding station, flipping station, first loading station, and second loading station; Based on the mutual exclusion relationship of the equipment, when the first riveting and welding platform is in the welding station or the flipping station, the moving base of the second riveting and welding platform is prohibited from moving to the welding station or the flipping station, while the second riveting and welding platform is allowed to perform centering operation at the second loading station.

[0030] The aforementioned equipment mutual exclusion relationship specifically includes: mutual exclusion between welding station and flipping station: only the first riveting and welding platform or the second riveting and welding platform is allowed to enter the welding station or flipping station at the same time; when either riveting and welding platform occupies the welding station or flipping station, the central controller locks the moving base drive signal of the other riveting and welding platform through the area interlock matrix.

[0031] In step S2, the welding robot welding process adopts a teach-free welding control method, specifically including: The central controller triggers the built-in vision controller of the welding robot to execute scanning instructions via the Modbus TCP protocol, performing 3D visual modeling of the current workpiece and generating planned welding paths and process parameters; The signal indicating the completion of the modeling is returned to the central controller. At the same time, the planned welding path and process parameters are sent to the welding robot's welding controller via Ethernet. After confirming that the modeling is complete, the central controller notifies the welding robot to start the welding program, ensuring that each weld seam is scanned before welding. During the welding process, the central controller collects welding parameters in real time and transmits the data to the workshop's MES system via industrial Ethernet. The workshop's laser weld seam tracking system calculates the deviation between the actual weld seam trajectory and the planned welding path to correct the welding trajectory.

[0032] During the welding process, the central controller collects welding parameters in real time and transmits the data to the workshop MES system via industrial Ethernet. Specifically, this includes: The central controller collects welding parameters in real time. These welding parameters include at least: weld position information, welding voltage, welding current, welding speed, welding time, welding wire consumption, instantaneous gas flow rate and cumulative consumption, workstation energy consumption, and equipment fault codes. The central controller has an open industrial Ethernet protocol interface, which connects to the workshop MES system via Ethernet. It uploads the welding parameters to the MES system and receives remote order tasks and process parameters issued by the MES system. The industrial Ethernet protocol interface includes, but is not limited to, OPC UA protocol and Modbus TCP protocol; Step S3: After the welding robot completes the welding of one side of the current workpiece, the central controller switches the state to the transport to the flipping position state and controls the moving base of the first riveting and welding platform to transport the workpiece to the flipping position, and notifies the flipping positioner to perform the flipping action; after the flipping action is completed, the central controller controls the first riveting and welding platform to transport the workpiece back to the welding position and continue welding the other side. In steps S1 and S3, the central controller controls the movement of the mobile base, specifically including: The central controller controls the moving base of the first or second riveting platform to move at a set speed via a servo driver; a positioning detection sensor is installed on the moving base's path to send a positioning signal to the central controller when the moving base reaches the target workstation, and the central controller responds to the positioning signal to control the servo driver to decelerate and stop.

[0033] Step S4: When the first riveting and welding platform completes all welding tasks, the state switches to the return state; the central controller reads the state variables of the second riveting and welding platform: if the second riveting and welding platform has completed alignment and is in an idle state, then the pre-switching logic is executed; The pre-switching logic in step S4 includes: The central controller controls the first riveting and welding platform to return from the welding station to the first loading station; Start the second riveting and welding platform and move it towards the welding station; The time interval between the first riveting and welding platform completely exiting the welding station boundary and the second riveting and welding platform starting to enter the welding station boundary shall not exceed 2 seconds.

[0034] In step S5, the second riveting and welding platform performs the welding, flipping, and return process of the next workpiece according to steps S2 to S4; at the same time, after the first riveting and welding platform returns to the first loading station, it switches to an idle state to allow the next workpiece to be loaded. Step S6: Repeat steps S2 to S5 until all workpieces are welded. Example 1 illustrates the implementation process of this application by taking a large gear welding project of a heavy equipment manufacturing enterprise as an example.

[0035] This project addresses the automated welding requirements of large welded gears for presses. The workpiece is a welded gear with a diameter of 1800mm and a weight of approximately 3200kg, made of a combination of 42CrMo gear ring and Q235 spokes. The welding process requires multi-layer, multi-pass welding, with 5-7 layers and 3-5 weld passes per layer required on a single side.

[0036] Before implementation, the gear to be welded is hoisted onto the first riveting and welding platform, and the workpiece is positioned and centered using the centering fixture. After centering, the central controller reads the status variable of the first riveting and welding platform, and the status variable changes from the centering state to the state of moving to the welding position. The central controller then controls the moving base of the first riveting and welding platform to move towards the welding position at a set speed through the servo drive. When the first riveting and welding platform reaches the welding position, the position detection sensor on the walking path sends a position signal to the central controller. The central controller responds to the signal and controls the servo drive to decelerate and stop. After the first riveting and welding platform arrives at the welding station, the central controller notifies the welding robot to start the welding program. Simultaneously, it controls the centering clamp of the first riveting and welding platform to release the thermal deformation stress generated during welding. Meanwhile, the second riveting and welding platform hoists and centers the next workpiece at the second loading station. The central controller applies a regional interlock to the second riveting and welding platform via a regional interlock matrix, locking its moving base drive signal to ensure that the second riveting and welding platform does not accidentally enter the welding station during welding. After the welding robot starts, the central controller triggers its built-in vision controller via the Modbus TCP protocol to execute 3D scanning instructions, performing 3D visual modeling of the current workpiece and generating a planned welding path and process parameters. After modeling is complete, the vision controller returns a modeling completion signal to the central controller and sends the planned welding path and process parameters to the welding controller via Ethernet. Once the central controller confirms the modeling is complete, it notifies the welding robot to start the welding program, with each weld seam undergoing a scan-before-weld process. During the welding process, the workshop's laser weld seam tracking system calculates the deviation between the actual weld seam trajectory and the planned welding path in real time and corrects the welding trajectory accordingly. The central controller collects parameters such as welding voltage, welding current, welding speed, welding wire consumption, and gas flow rate in real time and uploads them to the workshop's MES system via the OPC UA protocol. After single-sided welding is completed, the central controller switches the status to "transport to flipping position," controls the first riveting and welding platform's centering fixture to re-clamp the workpiece, transports the workpiece to the flipping position, and notifies the flipping positioner to perform a 180° flipping action. After the flipping is completed, the first riveting and welding platform transports the workpiece back to the welding position to continue welding the other side. When the first riveting and welding platform completes all welding tasks, its state switches to "return state". The central controller reads the state variables of the second riveting and welding platform. At this time, the second riveting and welding platform has completed alignment and is in "standby locked state". The central controller then executes the pre-switching logic: release the area interlock of the second riveting and welding platform, send a return command to the first riveting and welding platform, send a start command to the second riveting and welding platform, and acquire position sensor signals in real time. After confirming that the first riveting and welding platform has completely exited the welding station boundary, the second riveting and welding platform is allowed to enter the welding station. The idle time interval between the first riveting and welding platform completely exiting the boundary and the second riveting and welding platform starting to enter the boundary does not exceed 2 seconds. While the second riveting and welding platform continues to execute the welding process, the first riveting and welding platform returns to the first loading station and switches to idle state for the next workpiece to be loaded. Repeat the above process until all workpieces are welded.

[0037] After implementation of this embodiment, the welding robot operates continuously, which accelerates the average production pace of a single workstation and a single piece, and improves equipment utilization. The teach-free vision system automatically identifies weld features and generates planned welding paths, and can adapt to rapid production changes of gears of different specifications without manual teaching. The pass rate of ultrasonic flaw detection of welds has been steadily improved. The regional interlocking matrix ensures that the double riveting welding platform and the flipping positioner do not interfere or collide in a limited space.

[0038] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0039] like Figure 2 As shown, the following is an embodiment of an electrical control system for a large gear automatic welding workstation provided by this disclosure. This system belongs to the same inventive concept as the parallel scheduling method for electrical control of a large gear automatic welding workstation in the above embodiments. For details not described in detail in the embodiment of the electrical control system for a large gear automatic welding workstation, please refer to the embodiment of the parallel scheduling method for electrical control of a large gear automatic welding workstation described above.

[0040] The system includes: Welding robot, flipping and positioning machine, first riveting and welding platform, second riveting and welding platform, and central controller; The welding robot is located at the welding station, and the flipping and positioning machine is located at the flipping station; the first riveting and welding platform is located at the first loading station, and the second riveting and welding platform is located at the second loading station; the central controller has a built-in dual-station parallel scheduling state machine.

[0041] The dual-station parallel scheduling state machine includes: state variables of the first riveting and welding platform and the second riveting and welding platform; the state variables include at least: idle state, centering state, heading to welding position state, welding in progress state, heading to flipping position state, flipping in progress state and return state.

[0042] Both the first and second riveting platforms are equipped with a movable base and a centering clamp. The movable base is used to carry the workpiece and drive the workpiece to move between the first loading station, the second loading station, the welding station and the flipping station; The centering fixture is used to perform a loosening action during the centering process to release the thermal deformation stress generated in the workpiece during welding; the centering fixture is also used to perform a clamping action when transporting to the flipped position or the return position to fix the workpiece and prevent the workpiece from shifting during transportation.

[0043] This embodiment uses a central controller with a built-in dual-station parallel scheduling state machine to coordinate the collaborative operation of the welding robot, the flipping and positioning machine, and the two riveting and welding platforms. Each platform is equipped with a moving base and a centering fixture to realize the automatic transfer of workpieces between stations. During welding, the fixture is released to release thermal deformation stress, and during transportation, it is clamped and fixed to ensure that the large gears are efficiently and safely completed in an automated welding process.

[0044] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An electrical control system for a large-scale automatic gear welding workstation, characterized in that, include: Welding robot, flipping and positioning machine, first riveting and welding platform, second riveting and welding platform, and central controller; The welding robot is located at the welding station, and the flipping and positioning machine is located at the flipping station; the first riveting and welding platform is located at the first loading station, and the second riveting and welding platform is located at the second loading station; the central controller has a built-in dual-station parallel scheduling state machine.

2. The electrical control system of a large gear automatic welding workstation according to claim 1, characterized in that, The dual-station parallel scheduling state machine includes: state variables of the first riveting and welding platform and the second riveting and welding platform; the state variables include at least: idle state, centering state, heading to welding position state, welding in progress state, heading to flipping position state, flipping in progress state and return state.

3. The electrical control system of a large-scale automatic gear welding workstation according to claim 1, characterized in that, Both the first and second riveting platforms are equipped with a movable base and a centering clamp. The movable base carries the workpiece and drives the workpiece to move between the first loading station, the second loading station, the welding station and the flipping station; The centering fixture performs a releasing action during the centering process and a clamping action when moving to the flip position or returning to the original position.

4. A parallel scheduling method for electrical control of a large-scale automatic gear welding workstation, characterized in that, Includes the following steps: Step S1: After the first riveting and welding platform completes the workpiece hoisting and centering at the first loading station, the central controller controls the moving base of the first riveting and welding platform to move towards the welding station. Step S2: After the first riveting and welding platform arrives at the welding station, it notifies the welding robot to start welding. At the same time, the second riveting and welding platform centers the next workpiece at the second loading station, and the central controller applies area interlock to the second riveting and welding platform. Step S3: After the welding robot completes the welding of one side of the current workpiece, the central controller switches the state to the transport to the flipping position state and controls the moving base of the first riveting and welding platform to transport the workpiece to the flipping position, and notifies the flipping positioner to perform the flipping action; after the flipping action is completed, the central controller controls the first riveting and welding platform to transport the workpiece back to the welding position and continue welding the other side. Step S4: When the first riveting and welding platform completes all welding tasks, the state switches to the return state; the central controller reads the state variables of the second riveting and welding platform: if the second riveting and welding platform has completed alignment and is in an idle state, then the pre-switching logic is executed; In step S5, the second riveting and welding platform performs the welding, flipping, and return process of the next workpiece according to steps S2 to S4; at the same time, after the first riveting and welding platform returns to the first loading station, it switches to an idle state to allow the next workpiece to be loaded. Step S6: Repeat steps S2 to S5 until all workpieces are welded.

5. The electrical control parallel scheduling method for a large-scale automatic gear welding workstation according to claim 4, characterized in that, The area interlocking in step S2 uses the area interlocking matrix built into the central controller, specifically including: Define the mutual exclusion relationships between the equipment in the four areas: welding station, flipping station, first loading station, and second loading station; Based on the mutual exclusion relationship of the equipment, when the first riveting and welding platform is in the welding station or the flipping station, the moving base of the second riveting and welding platform is prohibited from moving to the welding station or the flipping station, while the second riveting and welding platform is allowed to perform centering operation at the second loading station.

6. The electrical control parallel scheduling method for a large-scale automatic gear welding workstation according to claim 5, characterized in that, The aforementioned equipment mutual exclusion relationship specifically includes: mutual exclusion between welding station and flipping station: only the first riveting and welding platform or the second riveting and welding platform is allowed to enter the welding station or flipping station at the same time; when either riveting and welding platform occupies the welding station or flipping station, the central controller locks the moving base drive signal of the other riveting and welding platform through the area interlock matrix.

7. The electrical control parallel scheduling method for a large-scale automatic gear welding workstation according to claim 4, characterized in that, In step S2, the welding robot welding process adopts a teach-free welding control method, specifically including: The central controller triggers the built-in vision controller of the welding robot to execute scanning instructions via the Modbus TCP protocol, performing 3D visual modeling of the current workpiece and generating planned welding paths and process parameters; The signal indicating the completion of the modeling is returned to the central controller. At the same time, the planned welding path and process parameters are sent to the welding robot's welding controller via Ethernet. After confirming that the modeling is complete, the central controller notifies the welding robot to start the welding program, ensuring that each weld seam is scanned before welding. During the welding process, the central controller collects welding parameters in real time and transmits the data to the workshop's MES system via industrial Ethernet. The workshop's laser weld seam tracking system calculates the deviation between the actual weld seam trajectory and the planned welding path to correct the welding trajectory.

8. The electrical control parallel scheduling method for a large-scale automatic gear welding workstation according to claim 7, characterized in that, During the welding process, the central controller collects welding parameters in real time and transmits the data to the workshop MES system via industrial Ethernet. Specifically, this includes: The central controller collects welding parameters in real time. These welding parameters include at least: weld position information, welding voltage, welding current, welding speed, welding time, welding wire consumption, instantaneous gas flow rate and cumulative consumption, workstation energy consumption, and equipment fault codes. The central controller has an open industrial Ethernet protocol interface, which connects to the workshop MES system via Ethernet, uploads the welding parameters to the MES system, and receives remote order tasks and process parameters issued by the MES system.

9. The electrical control parallel scheduling method for a large-scale automatic gear welding workstation according to claim 4, characterized in that, In steps S1 and S3, the central controller controls the movement of the mobile base, specifically including: The central controller controls the moving base of the first or second riveting platform to move at a set speed via a servo driver; a position detection sensor is installed on the moving path of the moving base, and the position detection sensor sends a position signal to the central controller when the moving base reaches the target workstation, and the central controller responds to the position signal to control the servo driver to decelerate and stop.

10. The electrical control parallel scheduling method for a large-scale automatic gear welding workstation according to claim 4, characterized in that, The pre-switching logic in step S4 includes: The central controller controls the first riveting and welding platform to return from the welding station to the first loading station; Start the second riveting and welding platform and move it towards the welding station; The time interval between the first riveting and welding platform completely exiting the welding station boundary and the second riveting and welding platform starting to enter the welding station boundary shall not exceed 2 seconds.

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