An automatic cutting and welding system for repairing hammer head of shell breaker

Abstract

An automatic cutting and welding system for repairing a shelling machine hammer head includes a suspended ring conveyor, the ring conveyor is connected to a control system, a plurality of hooks are arranged at intervals on the conveyor chain on the ring conveyor, the hooks move with the conveyor chain, and the ring conveyor includes loading and unloading workstations, cutting stations, and welding stations around the ring conveyor, a cutting robot is installed on the cutting station, and a hammer rod clamping mechanism, a hammer head clamping feeding mechanism, a second material detection sensor, and a welding robot are installed on the welding station. The present invention can be used in electrolytic aluminum enterprises to effectively reduce costs and improve efficiency.

Description

Technical Field

[0001] The invention relates to the repair and welding of a shell breaker hammer head, in particular to an automatic cutting and welding system for repairing a shell breaker hammer head, belonging to the technical field of automation equipment. Background Art

[0002] During electrolytic aluminum production, the shelling hammer heads work for long periods of time in environments with strong magnetic fields, high temperatures, and strong currents, and often require repair work. During repair, the shelling hammer heads need to be cut off from the long tube and a new hammer head welded to the remaining long tube. Currently, there are two modes for repairing shelling hammer heads: manual and semi-automatic. Manual repair involves manual cutting and welding, which is labor-intensive, has a harsh working environment, and is inefficient. Semi-automatic repair involves manual cutting followed by welding using an automated machine. It uses a single-axis rotary positioner to clamp the new shelling hammer head after assembly welding, placing the shelling hammer head horizontally and the welding gun pointing vertically downward, meaning the workpiece rotates while the welding gun remains stationary. Since the shelling hammer head often needs to be repaired, the round tube is no longer vertical and has a certain curvature. In this way, when welding, the shelling hammer head is not on the same axis when rotating, and the welding quality will be affected. The longer the time, the more times the repair is done, the more non-straight the round tube is, and finally it becomes impossible to weld automatically. Moreover, this semi-automatic repair mode is not efficient. The scale of electrolytic aluminum production enterprises is generally large. Taking a certain factory as an example, using the semi-automatic repair mode, no one can complete the repair of a maximum of 60 tubes per day, while the factory requires 180 tubes / day, which requires three skilled workers to complete. Therefore, there are problems of poor quality, low efficiency and high cost in the current shelling machine hammer head repair. Summary of the Invention

[0003] The purpose of the present invention is to overcome the above problems existing in the current repair of the hammer head of a shell breaker and to provide an automatic cutting and welding system for repairing the hammer head of a shell breaker.

[0004] To achieve the purpose of the present invention, the following technical solutions are adopted: an automatic cutting and welding system for repairing a shelling machine hammer head, comprising a suspended ring conveyor, the ring conveyor being connected to a control system, a plurality of hooks being arranged at intervals on a conveyor chain on the ring conveyor, the hooks moving with the conveyor chain, and a loading and unloading station, a cutting station, and a welding station being arranged around the ring conveyor, a cutting robot being installed at the cutting station, a first material detection sensor and a cutting clamping and positioning mechanism being also installed at the cutting station, the clamping and positioning mechanism comprising two clamping blocks with V-shaped clamping openings, one clamping block being fixedly arranged and the other clamping block being connected to a linear drive mechanism, or both clamping blocks being connected to a linear drive mechanism, and the material to be repaired passes between the two clamping blocks;

[0005] The welding station is equipped with a hammer rod clamping mechanism, a hammer head clamping and feeding mechanism, a second material detection sensor and a welding robot. The hammer rod clamping mechanism is the same as the cutting clamping and positioning mechanism; the hammer head clamping and feeding mechanism includes a fixed long slot, the hammer heads are arranged in the long slot in sequence, a stepping cylinder is fixedly connected to the tail end of the long slot, the push rod of the stepping cylinder is located in the long slot, the movement direction of the cylinder rod of the stepping cylinder is consistent with the length direction of the long slot, and a clamping and pushing mechanism is connected to the outlet end of the long slot. The push-up mechanism includes a lifting mechanism, a U-shaped frame is installed at the moving end of the lifting mechanism, and a clamping cylinder is respectively installed on the two U-shaped opposite surfaces of the U-shaped frame, a clamping block with a V-shaped clamp is fixedly connected to the cylinder rod of the clamping cylinder, a limit plate is fixedly connected to the front of the U-shaped frame, and a limit block with a V-shaped groove is fixedly connected to the limit plate, and the limit block and the clamping block connected to the cylinder rod of the clamping cylinder are staggered in the upper and lower directions. After the hammer rod clamping mechanism clamps the hammer rod and the clamping and pushing-up mechanism clamps the hammer head, the hammer head and the hammer rod correspond to each other in the upper and lower directions;

[0006] All the above mechanisms and robots are connected to the control system.

[0007] Furthermore, a third material detection sensor is installed between the cutting station and the welding station.

[0008] Furthermore, a hammer collecting bucket is also installed on the cutting station.

[0009] Furthermore, the linear drive mechanism is a linear module.

[0010] Furthermore, the cutting robot and welding robot are both six-axis robots.

[0011] Furthermore; the hook is fixedly connected to the shaft of the joint bearing, the shaft is tightly fitted with the inner ring of the joint bearing, the outer ring of the joint bearing is installed in the bearing seat, the bearing seat is fixedly connected to the connecting plate, the connecting plate is fixedly connected to the conveyor chain, and a cylinder is integrally or fixedly connected to the shaft, a small round sleeve is provided on the upper and lower sliding sleeves of the cylinder, and a large round sleeve is connected under the small round sleeve. The inner diameter of the small round sleeve is adapted to the cylindrical surface, and the inner diameter of the large round sleeve is adapted to the outer diameter of the hammer rod.

[0012] Furthermore, a limiting piece is fixedly connected to the upper opening of the small round sleeve.

[0013] The positive and beneficial technical effects of the present invention are: the present invention can realize automatic cutting and welding in the repair of the shelling machine, the welding positioning is accurate, the centering between the hammer head and the hammer rod after welding is good, and the efficiency is high. It only requires an ordinary worker who does not require welding technology to complete it. The production efficiency of this system is equivalent to that of 3-4 skilled welding workers. It can be used in electrolytic aluminum enterprises to effectively reduce costs and improve efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is an overall schematic diagram of the present invention.

[0015] Figure 2 It is a schematic diagram of the hammer head clamping feeding mechanism.

[0016] Figure 3 It is a schematic diagram of the cutting station.

[0017] Figure 4 It is a schematic diagram of the welding station.

[0018] Figure 5 This is a schematic diagram of the hook connection. DETAILED DESCRIPTION

[0019] In order to more fully explain the implementation of the present invention, the following embodiments of the present invention are provided. These embodiments are merely illustrative of the present invention and do not limit the scope of the present invention.

[0020] The present invention is further explained in detail in conjunction with the accompanying drawings, in which the marks are: 1: ring conveyor; 2: cutting robot; 3: hammer head collecting bucket; 4: cutting clamping and positioning mechanism; 401: linear module; 402: clamping block; 5: first material detection sensor; 6: third material detection sensor; 7: welding robot; 8: second material detection sensor; 9: stepping cylinder; 10: long slot; 11: hammer rod; 12: hammer head; 13: push rod; 14: limit plate; 15: limit block; 16: lifting cylinder; 17: U-shaped frame; 18: clamping cylinder; 19: clamping block; 20: connecting plate; 21: bearing seat; 22: outer ring; 23: inner ring; 24: shaft; 25: cylinder; 26: small round sleeve; 27: large round sleeve; 28: limit plate; 29: hook; 30: hammer rod clamping mechanism.

[0021] As shown in the accompanying drawings, an automatic cutting and welding system for repairing the hammer head of a shelling machine includes a suspended ring conveyor 1, which is connected to a control system. A plurality of hooks are arranged at intervals on the conveyor chain on the ring conveyor, and the hooks move with the conveyor chain. In this embodiment, in order to make the clamping positioning more accurate, the hook specifically adopts the following mounting structure: the hook is fixedly connected to the shaft 24 of the joint bearing, the shaft is tightly matched with the inner ring 23 of the joint bearing, the outer ring 22 of the joint bearing is installed in the bearing seat 21, the bearing seat is fixedly connected to the connecting plate 20, and the connecting plate is fixedly connected to the conveyor chain. A cylinder 25 is integrally or fixedly connected to the shaft, and a small round sleeve 26 is provided on the upper and lower sliding sleeves of the cylinder. A large round sleeve 27 is connected to the lower part of the small round sleeve. The inner diameter of the small round sleeve is adapted to the cylindrical surface, and a limiting plate 28 is fixedly connected to the upper mouth of the small round sleeve. The limiting plate prevents the small round sleeve from falling off, and the inner diameter of the large round sleeve is adapted to the outer diameter of the hammer rod 11. There is a hanging hole on the upper end of the shell breaker hammer head. After hanging the hanging hole on the hook, the circular sleeve is enlarged downwards, and the hammer rod and the shaft almost become a rigid body. The shaking during movement and stopping can only occur at the joint bearing. The joint bearing has a large friction surface, which can effectively limit and reduce the error caused by the shaking of the hammer rod during positioning. In particular, the hammer head becomes lighter after being cut off, and the joint bearing can dampen the shaking, so that the axis of the hammer rod is in a vertical state after being clamped, which can effectively ensure the accuracy of the hammer head during repair. After this accuracy is guaranteed, the hammer head can be automatically repaired on this system many times.

[0022] Around the circular conveyor are loading and unloading stations, cutting stations, and welding stations. A cutting robot 2 is installed on the cutting station. A hammer head collection bucket 3 is also installed on the cutting station. The hammer head after cutting falls into the collection bucket. A first material detection sensor 5 and a cutting clamping and positioning mechanism 4 are also installed on the cutting station. The clamping and positioning mechanism includes two clamping blocks 402 with V-shaped clamping openings. One clamping block is fixedly set and the other clamping block is connected to a linear drive mechanism, or both clamping blocks are connected to a linear drive mechanism. In this embodiment, the linear drive mechanism is a linear module 401, one of which is fixedly set, and the material to be repaired passes between the two clamping blocks.

[0023] The welding station is equipped with a hammer rod clamping mechanism, a hammer head clamping and feeding mechanism, a second material detection sensor 8 and a welding robot 7. The hammer rod clamping mechanism is the same as the cutting clamping and positioning mechanism.

[0024] The hammer head clamping and feeding mechanism includes a fixed long slot 10, and the hammer heads to be welded are arranged in sequence in the long slot 10. A stepping cylinder 9 is fixedly connected to the tail end of the long slot. The push rod of the stepping cylinder is located in the long slot. The movement direction of the cylinder rod of the stepping cylinder is consistent with the length direction of the long slot. A clamping and pushing mechanism is connected at the outlet end of the long slot. The clamping and pushing mechanism includes a lifting mechanism. In this embodiment, the lifting mechanism adopts a lifting cylinder 16, and a lifting mechanism is installed at the moving end of the lifting mechanism. A U-shaped frame 17 has two opposing U-shaped surfaces, each with a clamping cylinder 18 mounted on it. A clamping block 19 with a V-shaped opening is fixedly connected to the cylinder rod of the clamping cylinder. A limit plate 14 is fixedly connected to the front of the U-shaped frame. A limit block 15 with a V-shaped groove is fixedly attached to the limit plate. The limit block and the clamping block connected to the cylinder rod of the clamping cylinder are vertically offset. After the hammer rod clamping mechanism clamps the hammer rod, and after the clamping and pushing mechanism clamps the hammer head, the hammer head and the hammer rod are aligned vertically. Each motion mechanism, robot, and material detection sensor are connected to a control system.

[0025] A third material detection sensor 6 is also installed between the cutting station and the welding station. The third material detection sensor 6 is used to detect whether the hammer head has been cut off. Each material detection sensor in this application can adopt a proximity switch or a photoelectric switch.

[0026] In the present application, both the cutting robot and the welding robot can be six-axis robots.

[0027] The working process of this application is as follows: a human or robot will install the shell hammer head that needs to be repaired on the hook. After installation, the suspension chain system will be controlled to move. When the sensor of the cutting station senses the shell hammer head, the computer will control the suspension chain system to stop running and control the fixture of the cutting station to clamp the shell hammer head. (The fixture is a V-shaped fixture, one end is fixed and the other end is pushed back and forth by a linear module.) After that, the computer controls the six-axis cutting robot to use plasma cutting to cut off the hammer head. The cut hammer head will fall into the collection bucket below and slide into the waste bin. After cutting is completed, the system controls the fixture to release and allows the suspension chain to continue moving. A third material detection sensor is installed in front of the sensing station to detect whether the hammer head has fallen. If it has fallen, the program will run normally. If it has not fallen, the computer will sound an alarm, the program will stop running, and wait for manual processing. When the second material detection sensor at the welding station detects the cut round tube of the shell hammer, the system controls the fixture to clamp it, and the feeding system pushes the hammer into the round tube, and the welding robot begins welding. After welding is completed, the feeding fixture is released, the fixture is released, the suspension chain continues to move forward, and the suspension chain system is removed manually or by machine at the first station.

[0028] After describing the embodiments of the present invention in detail, people familiar with the technology can clearly understand that various changes and modifications can be made without departing from the scope and spirit of the above-mentioned patent application. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are within the scope of the technical solution of the present invention, and the present invention is not limited to the embodiments of the examples given in the specification.

Claims

1. An automatic cutting and welding system for repairing a shelling machine hammer head, comprising a suspended ring conveyor, the ring conveyor being connected to a control system, a plurality of hooks being arranged at intervals on a conveyor chain on the ring conveyor, the hooks moving with the conveyor chain, characterized in that: The ring conveyor includes loading and unloading stations, cutting stations, and welding stations. A cutting robot is installed on the cutting station. A first material detection sensor and a cutting clamping and positioning mechanism are also installed on the cutting station. The clamping and positioning mechanism includes two clamping blocks with V-shaped clamping openings. One clamping block is fixedly arranged and the other clamping block is connected to a linear drive mechanism, or both clamping blocks are connected to a linear drive mechanism. The material to be repaired passes between the two clamping blocks. The welding station is equipped with a hammer rod clamping mechanism, a hammer head clamping and feeding mechanism, a second material detection sensor and a welding robot. The hammer rod clamping mechanism is the same as the cutting clamping and positioning mechanism; the hammer head clamping and feeding mechanism includes a fixed long slot, the hammer heads are arranged in sequence in the long slot, a stepping cylinder is fixedly connected to the tail end of the long slot, the push rod of the stepping cylinder is located in the long slot, the movement direction of the cylinder rod of the stepping cylinder is consistent with the length direction of the long slot, and a clamping and pushing mechanism is connected to the outlet end of the long slot, and the clamping and pushing mechanism includes a lifting mechanism A U-shaped frame is installed at the moving end of the lifting mechanism, and a clamping cylinder is installed on the two U-shaped opposite surfaces of the U-shaped frame respectively. A clamping block with a V-shaped clamp is fixedly connected to the cylinder rod of the clamping cylinder. A limit plate is fixedly connected to the front of the U-shaped frame. A limit block with a V-shaped groove is fixedly connected to the limit plate. The limit block and the clamping block connected to the cylinder rod of the clamping cylinder are staggered in the up-down direction. After the hammer rod clamping mechanism clamps the hammer rod and the clamping push-up mechanism clamps the hammer head, the hammer head and the hammer rod correspond to each other up-down; the above mechanisms and robots are all connected to the control system for control; A third material detection sensor is also installed between the cutting station and the welding station; The hook is fixedly connected to the shaft of the joint bearing, the shaft is tightly matched with the inner ring of the joint bearing, the outer ring of the joint bearing is installed in the bearing seat, the bearing seat is fixedly connected to the connecting plate, the connecting plate is fixedly connected to the conveying chain, a cylinder is integrally or fixedly connected to the shaft, a small round sleeve is provided on the upper and lower sliding sleeves of the cylinder, a large round sleeve is connected under the small round sleeve, the inner diameter of the small round sleeve is adapted to the cylindrical surface, and the inner diameter of the large round sleeve is adapted to the outer diameter of the hammer rod.

2. The automatic cutting and welding system for repairing the hammer head of a shell breaker according to claim 1, characterized in that: A hammer head collecting bucket is also installed on the cutting station.

3. The automatic cutting and welding system for repairing the hammer head of a shell breaker according to claim 1 is characterized by: The linear drive mechanism is a linear module.

4. The automatic cutting and welding system for repairing the hammer head of a shell breaker according to claim 1, characterized in that: The cutting robot and welding robot are both six-axis robots.

5. The automatic cutting and welding system for repairing the hammer head of a shell breaker according to claim 1 is characterized by: A limiting piece is fixedly connected to the upper opening of the small round sleeve.

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