Ultrasonic shot peening composite MIG welding equipment

Abstract

The utility model discloses ultrasonic shot peening composite MIG welding equipment, which relates to the technical field of welding and comprises a protective gas cylinder, a wire feeder, an MIG welding power supply, an integrated equipment upper computer, an ultrasonic power supply, an ultrasonic power supply integrated cabinet and a main body frame, a working table surface horizontal movement module, a three-dimensional movement module for driving the bearing overhanging arm to move, a movement module controller and an ultrasonic shot blasting component are arranged on the main body frame, and a welding gun clamp and a structured light sensor are fixedly arranged on the bearing overhanging arm. A molten pool is regulated and controlled through synchronous ultrasonic shot peening in the welding process, ultrasonic vibration in a molten pool area remarkably refines a solidification structure through the cavitation effect and the acoustic streaming effect, dendritic segregation is restrained, residual welding tensile stress can be effectively released through ultrasonic shot peening treatment loaded instantly after welding, and pressure stress is introduced; the effects of surface strengthening treatment and welding deformation improvement are achieved, and integrated regulation and control of the welding process and post-welding joint strengthening treatment are achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of welding, in particular to an ultrasonic shot peening composite MIG welding device. Background Art

[0002] Metal inert gas (MIG) welding holds a key position in industrial production due to its high production efficiency, stable welding quality, and outstanding material utilization. Metal inert gas (TIG) welding, on the other hand, excels with its stable arc, spatter-free process, and high-quality weld joints. Meanwhile, laser welding, with its advantages of high-speed welding, low heat input, and narrow heat-affected zone, has become a key processing method in modern manufacturing. While these three welding technologies each have their own unique characteristics, they still face numerous challenges in practical application. Arc welding suffers from high heat input, dispersed energy distribution, and limited current-carrying capacity of the tungsten electrode, which can easily lead to the formation of dendritic structures during molten pool solidification, resulting in coarse grains and residual stress accumulation in the joint. Laser welding, on the other hand, frequently produces porosity defects, which directly affect the mechanical properties of the joint. To overcome the limitations of traditional welding techniques, researchers have added various energy fields to assist the welding process, manipulate the molten pool, or perform appropriate post-weld treatments to improve joint performance. In particular, ultrasonic field-assisted welding technology has shown significant advantages through its multiple effects produced during the solidification process of the molten pool metal. The mechanical effect can refine the grain structure, the cavitation effect promotes the escape of impurities, and the acoustic streaming effect optimizes the melt flow, ultimately achieving a comprehensive improvement in the microstructure and mechanical properties of the welded joint. The current ultrasonic field introduction technology mainly adopts three coupling methods: base material conduction, welding wire conduction, and welding gun non-contact. The first two contact conductions require frequency matching through precisely designed amplitude rods to ensure that the system is in a resonant state to amplify the ultrasonic amplitude. Although the non-contact introduction of the welding gun avoids physical contact, it is affected by the attenuation of the air medium, and the actual ultrasonic energy transmitted to the molten pool is relatively limited.

[0003] While existing control methods have significantly improved weld joint performance, relying solely on dynamic molten pool control or single-stage post-weld processing still has significant limitations. This staged, discrete process design makes it difficult to achieve coordinated control of the welding process and joint performance evolution, resulting in optimization bottlenecks in the overall joint performance. Therefore, an ultrasonic shot peening combined with MIG welding equipment was proposed to address these issues. Utility Model Content

[0004] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: an ultrasonic shot peening composite MIG welding device, comprising a shielding gas cylinder, a wire feeder, a MIG welding power supply, an integrated equipment host computer, an ultrasonic power supply, an ultrasonic power supply integrated cabinet, and a main frame, wherein the main frame is provided with a worktable horizontal motion module, a three-dimensional motion module for driving the movement of a load-bearing cantilever arm, a motion module controller, and an ultrasonic shot peening component, and the load-bearing cantilever arm is fixedly provided with a welding gun fixture and a structured light sensor;

[0005] The ultrasonic shot peening components include an ultrasonic transducer height adjustment module fixed on the main frame, a transducer fixture connecting plate arranged on the ultrasonic transducer height adjustment module, an ultrasonic transducer fixture fixed on the transducer fixture connecting plate, a workpiece movement plane arranged on the worktable horizontal movement module, a workpiece fixture installed on the workpiece movement plane, a shot storage bin connecting plane fixed on the main frame, and a steel ball shot storage bin fixed on the shot storage bin connecting plane. The ultrasonic transducer fixture clamps and fixes the ultrasonic tool head, amplitude rod and ultrasonic transducer.

[0006] Preferably, the three-dimensional motion module includes an X-axis guide rail, a Y-axis guide rail and a Z-axis guide rail, wherein the X-axis guide rail is fixed on the main frame, the Y-axis guide rail is provided on the X-axis guide rail, the Z-axis guide rail is provided on the Y-axis guide rail, and the Z-axis guide rail is provided with a load-bearing cantilever arm.

[0007] Preferably, the worktable horizontal motion module is composed of two linear guide rail modules, and the two linear guide rail modules are commonly connected to a workpiece motion plane.

[0008] Preferably, three ultrasonic transducers are provided, and the center distance between every two adjacent ultrasonic transducers is 140 mm.

[0009] Preferably, the effective surface diameter of the ultrasonic tool head is 55 mm.

[0010] The utility model has the following beneficial effects:

[0011] By simultaneously controlling the molten pool during welding through ultrasonic shot peening, the ultrasonic vibrations in the molten pool significantly refine the solidification structure through cavitation and acoustic streaming effects, suppressing dendritic segregation. Furthermore, the immediate post-weld ultrasonic shot peening effectively releases residual tensile stresses and introduces compressive stresses, achieving surface strengthening and improving weld deformation, thus enabling integrated control of the welding process and post-weld joint strengthening. Furthermore, the reconfigurable ultrasonic transducer array design provides the equipment with excellent process adaptability, meeting the welding requirements of components of varying sizes and shapes. This results in a more efficient welding process, significantly refining grain size, improving microstructure, and enhancing weld mechanical properties. The equipment is equipped with independently developed online detection software, enabling real-time monitoring and feedback of weld surface morphology, molten pool conditions, and weld temperature during the welding process. This includes observing the flow state of the molten pool, the weld surface morphology, real-time monitoring and tracking of the molten pool and weld temperatures, and calculating and displaying the surface roughness of the weld joint. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0013] Figure 2 It is a schematic structural diagram of the ultrasonic shot peening component in the present utility model.

[0014] In the figure: 1, protective gas cylinder; 2, wire feeder; 3, MIG welding power supply; 4, work table horizontal motion module; 5, welding gun fixture; 6, structured light sensor; 7, load-bearing cantilever arm; 8, three-dimensional motion module; 9, motion module controller; 10, integrated equipment host computer; 11, ultrasonic power supply; 12, ultrasonic power supply integrated cabinet; 13-1, ultrasonic transducer height adjustment module; 13-2, transducer fixture connecting plate; 13-3, ultrasonic transducer fixture; 13-4, workpiece motion plane; 13-5, workpiece fixture; 13-6, shot storage bin connecting plane; 13-7, steel ball shot storage bin; 13-8, ultrasonic tool head; 13-9, amplitude transformer; 13-10, ultrasonic transducer; 14, main frame. DETAILED DESCRIPTION

[0015] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0016] The present invention will be described in further detail below with reference to the accompanying drawings and embodiments.

[0017] Embodiments of the present utility model

[0018] like Figure 1 and Figure 2 As shown, an ultrasonic shot peening composite MIG welding equipment includes a shielding gas cylinder 1, a wire feeder 2, a MIG welding power supply 3, an integrated equipment host computer 10, an ultrasonic power supply 11, an ultrasonic power supply integrated cabinet 12 and a main frame 14. The main frame 14 is provided with a work table horizontal motion module 4, a three-dimensional motion module 8 for driving the movement of a load-bearing cantilever arm 7, a motion module controller 9 and an ultrasonic shot peening component. The load-bearing cantilever arm 7 is fixedly provided with a welding gun fixture 5 and a structured light sensor 6.

[0019] The ultrasonic shot peening components include an ultrasonic transducer height adjustment module 13-1 fixed on the main frame 14, a transducer clamp connecting plate 13-2 arranged on the ultrasonic transducer height adjustment module 13-1, an ultrasonic transducer clamp 13-3 fixed on the transducer clamp connecting plate 13-2, a workpiece movement plane 13-4 arranged on the worktable horizontal movement module 4, a workpiece clamp 13-5 installed on the workpiece movement plane 13-4, a shot storage bin connecting plane 13-6 fixed on the main frame 14, and a steel ball shot storage bin 13-7 fixed on the shot storage bin connecting plane 13-6. The ultrasonic transducer clamp 13-3 clamps and fixes an ultrasonic tool head 13-8, an amplitude rod 13-9 and an ultrasonic transducer 13-10. The welding gun clamp 5 is used to clamp the welding gun; the workpiece clamp 13-5 is used to clamp and fix the welding workpiece; the worktable horizontal motion module 4 is used to drive the workpiece motion plane 13-4, the workpiece clamp 13-5 and the welding workpiece to move horizontally for shot peening, to ensure that the welding workpiece is evenly subjected to ultrasonic shot peening during the welding process and after welding is completed; the motion module controller 9 is used to control all motion modules to operate according to a predetermined program; the ultrasonic transducer height adjustment module 13-1 is used to support and drive the ultrasonic transducer 13-10, the ultrasonic tool head 13-8, and the amplitude rod 13-9 to move in the vertical direction, thereby adjusting the shot peening height; the shot storage bin connection plane 13-6 is used to install the steel ball shot storage bin 13-7 and provide a shot peening motion plane for the workpiece; the steel ball shot storage bin 13-7 is used to store shot peening steel balls and constrain the movement space of the steel balls during shot peening; the ultrasonic power supply integrated cabinet 12 is used to integrate the ultrasonic power supply 11 and the integrated equipment host computer 10.

[0020] like Figure 1 and Figure 2As shown, the three-dimensional motion module 8 includes an X-axis guide rail, a Y-axis guide rail, and a Z-axis guide rail. The X-axis guide rail is fixed to the main frame 14. The X-axis guide rail is provided with a Y-axis guide rail, the Y-axis guide rail is provided with a Z-axis guide rail, and the Z-axis guide rail is provided with a load-bearing cantilever arm 7. The three-dimensional motion module 8 is used to drive the load-bearing cantilever arm 7, the welding gun fixture 5, and the structured light sensor 6 to move in space. The ball screw in the three-dimensional motion module 8 is a fully enclosed type, each driven by an 86 closed-loop stepper motor, with a repeatability accuracy of ±0.05mm and an adjustable linear motion speed range of 0 to 80mm / s. The model of the X-axis guide rail can be FKM120-S700-SG-1605, the model of the Y-axis guide rail can be FKM120-S500-SG-1205, and the model of the Z-axis guide rail can be FKM120-S200-SG-1605.

[0021] The worktable horizontal motion module 4 is composed of two linear guide rail modules, and the two linear guide rail modules are commonly connected to the workpiece motion plane 13-4. The model of the linear guide rail module can be FKM80-S900-SG-1605.

[0022] Three ultrasonic transducers 13-10 are provided, with the center distance between each two adjacent ultrasonic transducers 13-10 being 140 mm. The active surface diameter of the ultrasonic tool head 13-8 is 55 mm. Three ultrasonic power supplies 11 are provided, each connected to the three ultrasonic transducers 13-10. The three ultrasonic transducers 13-10 are connected in parallel. When one ultrasonic transducer 13-10 fails, the normal operation of the other ultrasonic transducers 13-10 is not affected. In actual application, the topology of the ultrasonic transducers 13-10 can be flexibly configured according to different welding process requirements, including but not limited to various arrangement patterns such as linear array, triangular matrix, and quadrilateral grid.

[0023] It should be noted that the protective gas cylinder 1, wire feeder 2, MIG welding power supply 3, structured light sensor 6, motion module controller 9, integrated equipment host computer 10, ultrasonic power supply 11, ultrasonic power supply integrated cabinet 12, ultrasonic tool head 13-8, amplitude transformer 13-9 and ultrasonic transducer 13-10 are all existing technologies, the work table horizontal motion module 4, three-dimensional motion module 8 and ultrasonic transducer height adjustment module 13-1 are all electrically connected to the motion module controller 9, and the wire feeder 2, MIG welding power supply 3, structured light sensor 6, motion module controller 9 and ultrasonic power supply 11 are all electrically connected to the integrated equipment host computer 10. Among them, the model of MIG welding power supply 3 can be FastMig X350, and the model of wire feeder 2 can be FastMig WFX300-T, both of which are produced by KEMPPI of Finland. FastMig X350 is a multi-process constant voltage and constant current power supply suitable for unified and pulsed metal arc gas shielded welding, MMA welding and argon arc welding, equipped with multi-process power supply solutions such as MIG, 1-MIG, pulsed MIG, MMA and TIG, and its equipped Arc Mobile The control system allows for flexible operation and control of the welding machine, accurately measuring arc voltage and displaying it on the display. The motion module controller 9 utilizes a 6-axis PLC-based motion control solution. The core controller is the ETH-NEC-NLM model, enabling precise control of the servo motor via the EtherCAT bus protocol. It supports the LabVIEW graphical programming environment and direct transfer of CAD / DXF drawings, is compatible with multi-language secondary development environments such as C, C++, Python, and Arduino, and features a touchscreen interface. The ultrasonic power supply 11 can be a CONPROFE brand intelligent CNC ultrasonic generator. The structured light sensor 6 can be a KEYENCE LJ-X8020 fully automatic laser scanning 3D vision sensor, enabling high-precision and stable 3D detection without complex adjustments. It can simultaneously acquire multi-dimensional information such as the target's height, width, and depth, significantly improving detection accuracy and stability. The integrated equipment host computer 10 is equipped with online detection software, which runs through the host computer to provide real-time monitoring and feedback on the weld surface morphology, weld pool state, and weld temperature during the welding process.

[0024] During welding, the ultrasonic shot peening components vibrate the molten pool, and after welding, the ultrasonic shot peening components immediately load the ultrasonic shot peening treatment. This utility model adopts a composite control mechanism of "ultrasonic shot peening vibrates the molten pool + ultrasonic shot peening strengthens the weld joint" to achieve integrated control of the welding process and post-weld joint strengthening treatment. A modular ultrasonic generating system is used, with multiple sets of adjustable ultrasonic transducer 13-10 arrays integrated at the bottom of the workpiece. Energy is input to the steel balls through the ultrasonic transducers 13-10, which simultaneously drive the mechanical vibration of the welded workpiece while shot peening the post-weld joint. This inputs ultrasonic energy into the weld pool, achieving integrated control of the weld joint and the molten pool.

[0025] By simultaneously performing ultrasonic shot peening during welding, the weld pool is regulated. Ultrasonic vibrations in the weld pool significantly refine the solidification structure through cavitation and acoustic streaming effects, suppressing dendritic segregation. Furthermore, the immediate post-weld ultrasonic shot peening effectively releases residual tensile stresses and introduces compressive stresses, achieving surface strengthening and improving weld deformation. Furthermore, the reconfigurable 13-10 array of ultrasonic transducers provides the equipment with excellent process adaptability, meeting the welding requirements of components of varying sizes and shapes. This significantly improves the welding process, significantly refining grain size, improving microstructure, and enhancing weld mechanical properties. The equipment is equipped with independently developed online detection software, enabling real-time monitoring and feedback of weld surface morphology, weld pool conditions, and weld temperature during the welding process. This includes observing the flow state of the weld pool, weld surface morphology, real-time monitoring and tracking of the weld pool and weld temperatures, and calculating and displaying the surface roughness of the weld joint.

[0026] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An ultrasonic shot peening composite MIG welding equipment, characterized in that, The invention comprises a protective gas cylinder (1), a wire feeder (2), a MIG welding power source (3), an integrated equipment host computer (10), an ultrasonic power source (11), an ultrasonic power source integrated cabinet (12) and a main frame (14); the main frame (14) is provided with a work table horizontal motion module (4), a three-dimensional motion module (8) for driving a load-bearing cantilever arm (7) to move, a motion module controller (9) and an ultrasonic shot peening component; the load-bearing cantilever arm (7) is fixedly provided with a welding gun fixture (5) and a structured light sensor (6); The ultrasonic shot peening component comprises an ultrasonic transducer height adjustment module (13-1) fixed on a main frame (14), a transducer fixture connecting plate (13-2) arranged on the ultrasonic transducer height adjustment module (13-1), an ultrasonic transducer fixture (13-3) fixed on the transducer fixture connecting plate (13-2), a workpiece motion plane (13-4) arranged on a worktable horizontal motion module (4), a workpiece fixture (13-5) mounted on the workpiece motion plane (13-4), a shot storage bin connecting plane (13-6) fixed on the main frame (14), and a steel ball shot storage bin (13-7) fixed on the shot storage bin connecting plane (13-6); an ultrasonic tool head (13-8), an amplitude rod (13-9), and an ultrasonic transducer (13-10) are clamped and fixed on the ultrasonic transducer fixture (13-3).

2. The ultrasonic shot peening composite MIG welding equipment according to claim 1, characterized in that: The three-dimensional motion module (8) includes an X-axis guide rail, a Y-axis guide rail, and a Z-axis guide rail, wherein the X-axis guide rail is fixed to the main frame (14), the Y-axis guide rail is provided on the X-axis guide rail, the Z-axis guide rail is provided on the Y-axis guide rail, and the Z-axis guide rail is provided with a bearing cantilever arm (7).

3. The ultrasonic shot peening composite MIG welding equipment according to claim 2, characterized in that: The worktable horizontal motion module (4) is composed of two linear guide rail modules, and the two linear guide rail modules are commonly connected to a workpiece motion plane (13-4).

4. The ultrasonic shot peening composite MIG welding equipment according to claim 2, characterized in that: Three ultrasonic transducers (13-10) are provided, and the center distance between every two adjacent ultrasonic transducers (13-10) is 140 mm.

5. The ultrasonic shot peening composite MIG welding equipment according to claim 2, characterized in that: The active surface diameter of the ultrasonic tool head (13-8) is 55 mm.

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